Useful energy product

ABSTRACT

A useful energy product created by a process where a chemical species flow passes through a macroscopic artificial dielectric structure for a gas-permeable susceptor having (a) first regions in the structure that are primarily transparent to applied electromagnetic energy and (b) second regions in the structure that are not primarily transparent to applied electromagnetic energy.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation-in-part or U.S. patentapplication Ser. No. 10/351,768, filed on 27 Jan. 2003, allowed andwhich will issue as U.S. Pat. No. 7,176,427 on 13 Feb. 2007, which is acontinuation-in-part of U.S. patent application Ser. No. 09/897,268,filed on 2 Jul. 2001, which issued as U.S. Pat. No. 6,512,215 on 28 Jan.2003, which is a divisional of U.S. patent application Ser. No.09/402,240, filed on 29 Sep. 1999, which issued as U.S. Pat. No.6,271,509 B1 on 7 Aug. 2001, which is the US National Phase underChapter II of the PCT of PCT Patent Application No. PCT/US98/06647,which published as International Publication No. WO 98/46046 on 15 Oct.1998, which claims the benefit of U.S. Provisional Patent ApplicationNo. 60/041,942, filed on 4 Apr. 1997, all of which are incorporatedherein by this reference.

BACKGROUND OF THE INVENTION

1. Field of Invention

This invention relates to a useful energy product created by a processwhere a chemical species flow passes through a macroscopic artificialdielectric structure for a gas-permeable susceptor consisting of firstregions in the structure that are primarily transparent to appliedelectromagnetic energy and second regions in the structure that are notprimarily transparent to applied electromagnetic energy.

2. Prior Art

The scope of this current invention is a device for thermal treatment ofchemical species that employs 1) alternate cavity and susceptorgeometries for providing more homogeneous interactions of appliedelectromagnetic energy in the volume of the susceptor regardless of theflow rate and diameter of the exhaust duct width, 2) heat transfermethods to improve the overall heat efficiency of the device, 3) asusceptor structure that has reflectivity as principle mode ofinteraction with applied electromagnetic energy, which allows for energyto penetrate a susceptor, 4) composite susceptor materials, 5) a simplemethod of controlling the temperature versus energy concentration in thesusceptor, and 6) field concentrators to concentrate the energy densityof the applied electromagnetic energy.

Cavity geometries in these devices affect the optical properties of theelectromagnetic energy within the susceptor. Electromagnetic energy,whether ultraviolet, infrared, microwave or radio frequencies, exhibitsthe same optical properties as the visible spectrum when interactingwith geometric shapes and surfaces that are similar to a lens. Theelectromagnetic energy in a susceptor can either converge or diverge dueto the geometric shape of the susceptor following the same principles asoptical lenses. Additionally, the modes of propagation of theelectromagnetic energy are dependent upon the cavities geometry. Thesemodes effect the distribution of electromagnetic energy in the cavity.These modes are different for cylindrical and rectangular cavities (see,e.g., Handbook of Microwave Engineering).

Electromagnetic energy that is incident perpendicular to the perimeterof the circular cross-section of a cylindrical susceptor will convergeinitially, concentrating the energy within the cross-section. Thisconcentration will cause the material inside the susceptor to absorbmore energy than the material near the surface, changing the dielectricproperties of the material inside the cross-section. This concentrationof energy can make the material, which is located in the susceptor'sinterior, between the center and the perimeter, to absorb more energy,thereby reducing the depth of penetration of the material due to thesusceptor's geometry.

The optical properties of rectangular cavities and planar surfaces aredifferent. Rectangular cavities with a susceptor having a rectangulargeometry and planar surfaces will follow the optical properties of aflat surface. A flat surface does not concentrate or disperse energy asdo curved surfaces, such as convex and concave surfaces. With a flatsurface of incidence for applied electromagnetic energy, the absorptionof electromagnetic energy in a susceptor is due only to the propertiesof the materials and is not influenced by energy, which is concentratedby curved geometries. Incident energy on susceptors with flat surfaceswill not be concentrated within a structure with homogeneous material,and the depth of penetration will be influenced by the incident energy'spower, the electric fields and magnetic fields inside the susceptor.Conversely, incident energy on susceptors with curved geometry can beconcentrated within a susceptor with homogeneous materials, and thedepth of penetration of the energy will be influenced by the ability ofthe curved surface to concentrate energy inside the susceptor.

The overall energy efficiency of such devices for thermal treatment ofchemical species can be improved with a better heat transfer process tocapture the energy that is lost from cooling the tube that is the sourcefor the applied electromagnetic energy. In industrial microwave dryingoperations, the heat produced from cooling the magnetrons with air isapplied to the articles that are being dried with the microwaves. Thissynergistic drying, which uses hot air and microwaves, increases theenergy efficiency of the drying process.

Alternative composite materials and susceptor structures can be used tofacilitate the thermal treatment of chemical species. These compositematerials and susceptor structures are known as artificial dielectrics.

Artificial dielectric structures date back to the 1940s. Artificialdielectrics were used as lenses to focus radio waves for communication.Artificial dielectrics use conductive metal plates, rods, spheres anddiscs (second phase material) which are embedded in matrices of lowdielectric constants and low dielectric losses to increase the index ofrefraction, thus reducing size of a lens to achieve the desired opticalproperties. The second phase material reflects the energy and usesdiffuse reflection to transmit electromagnetic energy. These plates,rods, spheres, and discs can be arranged in a lattice structure toproduce an isotropic or an anisotropic structure.

When conductive elements are embedded in a low dielectric constant andlow dielectric loss matrix, the effect of these on the matrix material'sdielectric loss factor is negligible and the dielectric constant of thecomposite lens is increased. However, these above effects are limitedand influenced by the size, shape, conductivity and volume fraction ofthe material embedded in a matrix of low dielectric loss, low dielectricconstant of the material as well as the wavelength of the incidentradiation. The dielectric strength and complex dielectric constant ofthe matrix material plays important additional roles in the design ofartificial dielectric lenses. On the other hand, selection of matrixmaterials with different dielectric properties and incorporation ofsecond phase materials such as semiconductors, ferroelectrics,ferromagnetics, antiferroelectrics, antiferromagnetics, dielectrics withhigher dielectric losses, and dielectrics with conductive losses thatproduce absorption of microwave energy, produce heat in an artificialdielectric.

Lossy artificial dielectrics were demonstrated by the 1950s andsubsequently used at the microwave frequencies to sinter ceramicarticles, in food packaging for heating foodstuffs, in browningapparatuses for foodstuffs, in consumer products, and to renderadhesives flowable for bonding applications.

The structure of the artificial dielectrics determines theelectromagnetic properties. When the volume fraction of the second phasematerials inside the artificial dielectric reaches a certain level, theartificial dielectric will reflect incident electromagnetic energy,shielding the artificial dielectric from absorbing electromagneticenergy. The volume fraction of the second phase material at which theartificial dielectric shields electromagnetic energy is dependent on thesecond phase material's reflectivity, the shape of the second phasematerial, and the temperature. By controlling the amount of reflection,the susceptor's reflectivity can be used to control the susceptor'stemperature.

Reflectivity has been used to produce structures that have aself-limiting temperature. Producing reflectivity in dielectrics isexplained in Von Hipple's Dielectrics and Waves. Using such principles,devices have been designed to have self-limiting temperatures.Self-limiting temperatures have also been theorized for materials withCurie temperatures. The reflectivity of electromagnetic energy isrelated to a material's conductivity. Metals are electrically conductiveat room temperatures and reflective of electromagnetic energy.Semiconductors and ionic conductors have low moderate conductivity atroom temperature. At elevated temperatures semiconductors and ionicconductors have increased conductivity, and these materials will becomereflective to electromagnetic energy at elevated temperatures. Theamount of reflectivity of a material at elevated temperature will alsobe dependent upon the wavelength of incident electromagnetic energy.

The artificial dielectrics structure can be used to produce diffusereflection, or scattering, inside a susceptor. The second phasematerials either can be reflective materials at room temperature, suchas a metal, or can become reflective at elevated temperatures due to 1)increasing conductivity, such as semiconductors and ionic conductorsand/or 2) exceeding the Curie temperature, such as ferroelectrics andferromagnetics. This diffuse reflection may also be used to control thetemperature of a given susceptor that uses the artificial dielectricstructure.

Regardless of the structure of a susceptor and its materials ofconstruction, applied energy must be applied to penetrate the structureand material or materials of construction for volumetric interactionbetween the susceptor and the applied energy.

Other considerations must be given to the structure of a susceptor in adevice for thermal treatment of chemical species. Honeycombs, foams,packed material and woven structures, which are constructed of amaterial that either has an increased dielectric conductivity atelevated temperatures or has a Curie temperature below the operatingtemperature could become reflective. If the material becomes reflective,then the susceptor's structure either could a) act as waveguides withdimensions that would not allow the applied energy to penetrate becausethe applied energy would be below the cut-off frequency for thesusceptor's structure or b) shield the electromagnetic energy frompenetrating into the susceptor. The Handbook of Microwave EngineeringHandbook explains waveguide theory in more detail. For example, granularsuscepting structures employed in U.S. Pat. No. 4,718,358 for treatmentof gases exemplify conditions where the susceptor's structure may notallow for incident electromagnetic energy penetrate the volume of thesusceptor.

It seems to appear that the authors of U.S. Pat. No. 4,718,358preferably embody granular absorbing material in the range of about 5 mmto 10 mm with a layer thickness, which is preferably 100 mm to 300 mm.One of the preferred absorbing materials is Sic in granular form.Silicon carbide, a semi-conducting ceramic, has a moderate penetrationdepth of approximately 10 cm at room temperature. And, depending uponthe purity of the Sic, the depth of penetration can be less then 2 cm atroom temperature. At elevated temperatures, silicon carbide becomes moreconductive, thus having an even lower penetration depth. If one assumesthat the granules in U.S. Pat. No. 4,718,358 are spherical, then the 10mm spheres of the Sic would most likely pack inside the cylindricalcavity in what is known as the close-packed cubic structure. Theclose-packed cubic Sic structure would have a void volume of only 26%.The largest void space in this granular pack of 10 mm Sic spheres in theclose-packed cubic structure would be occupied by what is known as anoctahedral site. The octahedral site is the void space between sixspheres—four spheres touching in one plane, one on the top of and one onthe bottom of the void space formed between the four-spheres touching inone plane. The void diameter of the octahedral site at the largestdiameter would be about 6 mm. With an open space of the 6 mm in widthand the device in U.S. Pat. No. 4,718,358 operating at approximately900° C., where the dielectric conductivity of Sic is greatly increasedin comparison to the dielectric conductivity at room temperature, onecan question the ability of the microwave energy at 2.45 GHz andwavelength of approximately 13 cm to propagate through the close-packcubic structure of the Sic granules and heat a volume of Sic with adepth of the particles being between 100 mm to 300 mm. Does the packedSic spheres at the operating temperature of 900° C. act as a collectionof small waveguides that have dimensions below the cut off frequency forthe applied electromagnetic radiation? If so, the susceptor's structurewill not allow for the applied energy to penetrate into the entirevolume of Sic granules. This type of structure would shieldelectromagnetic energy as exemplified in common practice by windows ofhousehold microwave cooking ovens. Or, does the packing of Sic spheresat an operating temperature of 900° C. have a finite depth ofpenetration that neither allows for the volumetric heating of the entiremass of Sic granules nor has electromagnetic energy throughout thevolume of the Sic mass to interact with gaseous species for possibleenhanced reactions? This latter argument for a finite depth ofpenetration in this susceptor arrangement would most likely heat afinite volume of Sic granules near the surface of the incident appliedradiation, then heat would be thermally conducted through the Sic to theremaining volume of Sic granules since Sic is a very thermallyconductive material. One could argue that a greater power level ofapplied electromagnetic energy could be incident on the Sic granules inan attempt to heat the entire volume, however depth of penetration canbecome less at increased levels of applied power. The greater powerlevel will cause the depth of penetration to migrate to the surfacewhere the applied electromagnetic energy is initially incident upon,when the Sic material becomes more conductive at elevated temperature.The increased conductivity can cause the material to become reflectiveto the applied energy.

Other suscepting structures such as honeycombs, foams and wovenstructures can have similar concerns about the depth of penetrations asmentioned above. These structures, when made of semiconducting,conducting, ferromagnetic, ferromagnetic, ferroelectric andantiferroelectric materials, can have shallow depths of penetration.Graphite, carbon black, magnetite (Fe₃O₄), MnO₂ are materials that havedepths of penetration less than 1 mm at room temperature. Whensuscepting structures, such as honeycombs, foams and weaves are coatedwith these material, the structures either will have shallow penetrationdepths or will act as waveguides that have dimensions that are below thecutoff frequency regardless of a) the bulk material or materials thatmakes up the substrate for the coating and b) the design of thesusceptor's structure. Consequently, a susceptor must be properlydesigns for volumetric interaction with the electromagnetic energy,taking into consideration the materials of construction, the structureand the effects of coatings.

BRIEF SUMMARY OF INVENTION

This present invention, in its broadest sense, is an improved designthat will produce a more homogeneous distribution of energy by 1) thedesign of the cavity geometry, 2) the location of the applied energysources, and 3) the depth of penetration of the susceptor. The morehomogeneous distribution of energy in the susceptor will provide for theinvention to have the applied electromagnetic energy distributedvolumetrically to a) produce heat, b) be present for interaction withchemical species to promote chemical reaction throughout the susceptor,c) to produce fluorescent radiation, and d) to produce thermoluminescentradiation.

The cavity geometry can use polygons that have a cross-section that isirregular shaped, having four (4) or more sides, and preferably arectangle where the cross-sectional area of the rectangle isperpendicular to the direction of flow of the gas stream. The preferredrectangle shape has the location of the applied energy source onopposing faces of the longest parallel sides. The shortest distance ofthe irregular-shaped rectangular cross-section is referred to as thewidth. The width is designed to promote a homogenous distribution ofenergy by design. This design is based upon the depth of penetration ofthe susceptor by the applied electromagnetic energy. The depth ofpenetration of the susceptor is used instead of the depth of penetrationof a material because the susceptor includes the void fraction, thematerial, materials or composite materials of construction and thesusceptor's structure. The depth of penetration of the susceptor isdefined similar to the depth of penetration for a material as mentionedearlier as a value of 1/e. The value of 1/e is equivalent to 67% of theenergy being absorbed or scattered.

The cavity geometry together with the location of the applied energysources and depth of penetration of the susceptor play an important rolein the device. As the energy sources are located on opposing faces ofthe irregular-shaped rectangle, the distance of one half the width,being the distance from the center of the cross-sectional area to theside of the cavity where the applied energy source is located, isdefined in this invention as the width of interaction. The width ofinteraction is similar to the depth of penetration. The width ofinteraction is used to bisect the susceptor in half to define the depthof penetration of the susceptor upon the half width of the cavity andthe susceptor's surface closest to the location of the applied energysources as described above. The width of interaction is used to describethe amount of energy that is available for interaction within thesusceptor to produce methods that promote chemical reaction anddestruction of pollutants, whereas commonly the depth of penetration ofelectromagnetic energy describes the about of power attenuated inmaterial. Attenuation can result in a material by a) absorption ofenergy to produce heat or b) reflection of the applied energy. In thisinvention, the penetration depth of the susceptor can be use to providefor the reaction of chemical species, such as for example gases, byeither 1) a method that primarily produces heat for thermal treatment,2) a method that primarily uses the applied electromagnetic energy forinteraction with gaseous/particulate species for chemical reaction, 3) amethod that produces fluorescent radiation, 4) a method that producesthermoluminescent radiation, 5) a method that produces scattering of theapplied electromagnetic energy for concentrating the applied energy, or6) a combination of these five methods. The combination of the methodswould be best suited for the purpose at hand. The following examplesdemonstrate these primary methods:

Example One: If thermal treatment is needed as the primary method forchemical reaction, then adsorption of electromagnetic energy by thesusceptor is needed to produce heat in the range for thermalincineration (600-1000° C.) or for catalytic treatment (300-600° C.). Toproduce volumetric heating in the susceptor by the appliedelectromagnetic energy at the operating temperature, then the appliedenergy must penetrate the entire width of interaction inside the cavityat the operating temperature. Therefore, the electromagnetic energy mustbe absorbed by the susceptor, and the depth of penetration of thesusceptor at the operating temperature must allow for the appliedelectromagnetic energy to volumetrically heat the width of interaction.For thermal treatment as the primary method, where the shape of thecavity for this device is an irregular-shaped polygon and the locationof the source of the applied electromagnetic energy is as mentionedabove, the depth of penetration of the susceptor should be approximatelyequivalent to one-third the entire width of susceptor. The depth ofpenetration of the susceptor being approximately ⅓ the width of thesusceptor allows for approximately 50% of the total energy in the cavityfrom the sources of applied energy, which is located at opposing faces,to be present in the width of interaction and to be absorbed by thesusceptor's material or materials of construction.

Example Two: If interaction of electromagnetic energy with the chemicalspecies is the primary method for chemical reaction, then to producevolumetric interaction of electromagnetic energy with the chemicalspecies the applied energy must penetrate the width of interactioninside the cavity at the operating temperature. Therefore, theelectromagnetic energy must be able to penetrate the susceptor, and thedepth of penetration of the susceptor at the operating temperature mustallow for the applied electromagnetic energy to volumetrically interactwith the chemical or particulate species for treatment in the width ofinteraction. In this method a susceptor may be used to produceturbulence so the chemical species can mix or be mixed for betterconversion of reactant species to product species.

For volumetric interaction of electromagnetic energy with the chemicalspecies, where the shape of the cavity for this device is anirregular-shaped polygon and the location of the source of the appliedelectromagnetic energy is as mentioned above, the depth of penetrationof the susceptor is not as important for this method unless thesusceptor was designed to scatter the applied electromagnetic energy.The depth of the penetration of the susceptor would be designed from amaterial or materials that are primarily transparent to the appliedelectromagnetic energy in order to maximize the amount of applied energyto be present to drive the reaction. Additionally, the susceptors coulduse field-concentrators to increase the strength of the electromagneticenergy (the use of field-concentrators will be disclosed later in thissection). The depth of penetration of the susceptor for this method foreither reacting chemical species would be greater than the entire widthof the susceptor and allow for approximately 50% of the total energy inthe cavity from the sources of applied energy, which is located atopposing faces, to be present in the width of interaction forinteraction between the applied energy and gaseous/particulate species.However, if scattering the applied energy is the desired for this methodof treatment, then the depth of penetration should be about ⅓ the widthof the susceptor.

Example Three: If a combination of treatment methods is needed as thebest method for chemical reaction, then adsorption, transmission,reflection and scattering of electromagnetic energy or energies by thesusceptor may be required. Absorption of the applied electromagneticenergy in the susceptor either could produce heat, or could producefluorescent radiation emissions, thermoluminescent radiation emissionsor assist in producing fluorescent radiation. For example, an appliedultraviolet (UV) energy source can be used to produce phosphorescentradiation in a susceptor or at a field concentrator for interactionbetween the phosphorescent radiation and the gaseous/particulate speciesto drive the reaction. The applied UV energy can also interact with thegaseous/particulate species. Such a material for the susceptor or fieldconcentrator could be a phosphorescent material.

The depth of penetration of susceptor must allow for applied UV energyto penetrate the susceptor for volumetric interaction a) with thesusceptor to produce fluorescent radiation and/or b) directly betweenthe applied UV energy and gaseous/particulate species. Consequently, ifUV and microwave energies are applied to the same susceptor, otherinteractions may occur between the applied energies, material ofconstruction of the susceptor, field concentrators and the gaseousspecies (or particulate). The UV energy that is applied to the cavitycan interact as previously mentioned, however the microwave energy a)may produce thermoluminescence in the phosphorescent materials b) mayproduce heat in the susceptor by the applied microwave energy and/or c)may enhance the phosphorescent radiation produce primarily by theapplied UV energy. Of other consequence, if the applied energy to thesame susceptor is only microwave energy then other interactions mayoccur. The microwave energy either a) may be completely absorbed forthermal treatment of the chemical species, b) may be partially absorbedand interact with the chemical species for interaction, c) may be usedto heat the susceptor and produce thermophosphorescence of UV radiation,which interacts with the chemical species, or d) a combination of thementioned interactions in a, b, and c.

This example, example three, demonstrates the potential complexity ofthe interaction of the applied electromagnetic energy, fluorescentradiation and thermoluminescent radiation with the susceptor's materialof construction and the susceptor's construction. As previouslymentioned in the Background section, the material or materials ofconstruction as well as the structure of the susceptor will influencethe ability of the applied electromagnetic energy or energies topenetrate and interact with the susceptor a) to produce heat, b) to bepresent for interaction with the gaseous/particulate species, c) toproduce fluorescence, and d) to produce thermoluminescence. Likewise,the ability of fluorescent and thermoluminescent radiation to penetratefinite distances within the susceptor's structure and interact with thegaseous/particulate species in the air stream for chemical reactioncould be of importance to the design of the susceptor. Fluorescentradiation could be phosphorescence, incandescence or fields generated bythermionic emissions or thermoelectricity emissions.

In example three, the transmission of, absorption of, reflectivity ofand scattering of each wavelength of energy that is present in thesusceptor becomes important. Instead of the susceptor being constructedof a material, the susceptor may better be constructed of more than onematerial, which will allow for the wavelength or wavelengths of theapplied electromagnetic energy or energies to penetrate andvolumetrically interact with the susceptor. And the construction anddesign of the susceptor and the susceptor's materials of constructionwill have to be chosen to prevent the design of the susceptor'sstructure from shielding the wavelength or wavelengths of the appliedelectromagnetic energy and energies. And also, transmission, absorption,reflectivity and scattering properties of the susceptor will be effectedby the bulk density of the materials of construction, as well as theporosity size, pore structure and amount porosity in the materials ofconstruction.

This invention, in its broadest sense, is an improved design which usescavity geometry that has a cross-section, which is perpendicular to theflow of the chemical species stream, and is shaped as an irregularshape, having four (4) or more sides, preferably a rectangle. Thepreferred rectangle shape has the location of the applied energy sourceon opposing faces of the longest parallel sides of the cross-sectionarea perpendicular to the flow of the chemical species stream. Thelocation of the applied energy source and the geometry of the cavity andsusceptor does not allow for the optical properties of the device toconcentrate energy, thus simplifying the design of a susceptor forinteraction with the applied electromagnetic energy and producing a morehomogeneous distribution of electromagnetic energy in the cavity.

When the susceptor is designed for a specific method a treatment of thechemical species stream, the design will be only be dictated by thedepth of penetration of the susceptor which is dependent upon the chosenwidth of interaction of the susceptor, since energy is not concentrated.Therefore, once a method for treatment of the chemical species stream ischosen, once an amount of power of the applied electromagnetic energy orenergies is chosen and once a width of interaction is decided upon toreduce the static-pressure in the device, the susceptor's materials ofconstruction and susceptor's structure can remain constant when thedevice is to be scaled for larger flow rates and larger exhaust ductwidth in commercial and industrial applications. To accommodate largerflow rates or larger exhaust duct widths, only the length of thecross-sectional area of the irregular-shaped polygon where the energysource or sources are located can simply be elongated. Unlikecylindrical cavities, the absorption properties of the susceptor'smaterial or material of construction do not have to be changed toaccommodate greater flow rates and larger duct widths of commercial andindustrial process for volumetric heating or interaction of the appliedenergy with the chemical species or gases inside the device susceptor.

With the design of the device in this invention, proper thermaltreatment of the chemical species to produce a useful energy product canbe achieved. Since this design simplifies the susceptor for producingheat at a wide variety of flow rates and duct widths, one can readilydesign devices for proper thermal treatment of chemical species byselecting an operating temperature and by sizing a length of a hot zonefor the required residence time at the operating temperature andturbulence in the susceptor. Thermal insulation around the susceptor maybe needed to prevent heat losses. Material that is transparent to theapplied electromagnetic energy or energies and that uses an aerogelstructure would be best suited for thermal insulation. An aerogel is astructure that has over 96% porosity and a bulk density of 4%. The hotzone's length would be designed in the coaxial direction of flow of theair stream where the direction is the defined breadth of the device.

In this broadest sense of the invention, the cavity's geometricalcross-sectional area perpendicular to the flow of the air stream and thesusceptor's width of interaction is designed to provide in this device amore homogenous distribution of energy with a given amount of appliedpower. With the more homogeneous distribution of energy, the inventionallows for one to design a method for specific treatment of chemicalspecies, such as gaseous and particulate species, compared to designingtreatment methods with devices that have geometries that concentrateelectromagnetic energy such as a cylinder. With this invention, thedepth of penetration of the susceptor by the applied electromagneticenergy or energy allows one to design methods of reactinggases/particulate species. When the depth of the penetration of thesusceptor is one third (⅓) the width of the susceptor's total width orgreater, the method of treatment of gases/particulate can be either 1)primarily thermal, 2) a combination of thermal, fluorescent,thermoluminescent, and interaction between the applied energy orenergies and the gas or particulate in the air stream, or 3) whenscattering of the applied energy is used to concentrate the appliedenergy without producing substantial heating of susceptor, such as witha low loss, low dielectric constant susceptor constructed with metallicspheres and fused silica, the device can primary treat by interactionbetween the applied energy or energies and the gas or particulate in theair stream.

The design is improved over the prior art because the prior art usedcylindrical geometries. Cylindrical geometries tend to concentrateenergy in a susceptor. Concentrated energy can lead to several problemswhen operating the device. One concern is the concentrated energypromotes conditions that lead to thermal runaway. The runaway can causethe susceptor's material or materials to melt, creating a pool of liquidmaterial in the susceptor. Another concern is that the concentratedenergy will not allow the applied energy to volumetric heat a susceptor.Such concentration will require the absorbing properties of thesusceptor's material of construction to be graded to counteract theconcentration, however this may not help. Also, susceptors incylindrical cavities are more difficult to scale up to greater flowrates and duct widths because of the absorption properties. Anotherconcern is that the concentrated energy can lead to deleterious reactionbetween composite materials and coatings on substrates. The deleteriousreaction can cause the materials to melt at eutectic temperature, causean article to become friable and alter the interaction between theapplied electromagnetic material and the susceptor, changing theproperties for subsequent use.

Another aspect of this invention is a heat transfer process to increasethe efficiency of such devices, which treat gases and chemical speciesfor chemical reaction. Commercially available magnetrons are generallybetween 65-70% efficient. Therefore 30-35% of the energy that isinitially put into the system is lost. An aspect of this invention is aheat transfer process for using that energy.

In this heat transfer process, heat is transferred between heat energythat is produced by the tube or tubes which supplies the appliedelectromagnetic energy and an input chemical species flow that cancontain gases and particulate species. The process uses the heat fromthe tubes or tubes to preheat the input chemical species flow, or partof the input chemical species flow, prior to it entering the device.This heat transfer process for preheating the input chemical speciesflow will decrease the cost of operating such a device. The heat fromthe tube, or tubes, can be exchanged with the input chemical speciesflow by such cooling fins that are found on commercial magnetrons, heatpipes, thermoelectric devices, or cooling systems that circulate a fluidaround the tube and release the heat at radiator. After the inputchemical species flow is preheated with heat from the tube, the inputchemical species flow can be further heated by heat transfer either a)from the cavity walls, b) from a conventional heat exchanger (arecuperator) that is located after the exit end of the device, or c)from both the cavity walls and a conventional recuperator.

Another aspect of this invention is a susceptor design that is describedin this invention as a gas-permeable macroscopic artificial dielectric.The gas-permeable macroscopic artificial dielectric susceptor device canbe a honeycomb structure, foam, or woven fabric filter with a pattern,or a structure consisting of discrete susceptors. The macroscopicartificial dielectric susceptor can be designed a) for a specific cavitygeometry, b) for a specific depth of penetration of applied andsubsequent radiation produced from the applied radiation, c) to betemperature self-limiting, or d) to produce, in the macroscopicartificial dielectric susceptor, a desired ratio of a self-limitedtemperature to power concentration of applied electromagnetic energy atone or more frequencies.

This aspect of the invention distinguishes the term artificialdielectric by using an artificial dielectric material and a macroscopicartificial dielectric susceptor. An artificial dielectric material isused to describe the case where an article is constructed of compositematerial consisting of two or more materials each with differentdielectric properties, where one material is the matrix and the othermaterial is or other materials are embedded in the matrix withoutsubstantial chemical reaction between the matrix and the embedded inmaterials. A macroscopic artificial dielectric susceptor is used todescribe a susceptor that is either a) an article constructed of amaterial where the article has a coating applied in a specific patternto create an artificial dielectric structure from the coating and thearticle, b) a woven structure that contains two or more differentmaterials as threads (or yarns) which woven together to form anartificial dielectric structure, or c) a structure that consists of amixture of discrete suscepting articles where the mixture containsdiscrete articles that have different dielectric properties and surroundeach other to form an artificial dielectric structure.

When the susceptor is a gas-permeable macroscopic artificial dielectricstructure that is a honeycomb structure constructed of materials, someof the cell walls of the honeycomb can be coated with materials thathave different dielectric properties to produce a macroscopic artificialdielectric. The pattern of cells with coated walls are arranged in thehoneycomb so that the applied electromagnetic energy and energiespenetrate the suscepting structure and either heat the susceptor orscatter the energy for interaction with the gases/particulate in the airstream. The pattern of the cell walls attenuate the appliedelectromagnetic energy by either a) partially or completely by absorbingthe applied energy, producing fluorescent radiation to heat theremaining parts of the susceptor and the air stream or b) partially orcompletely scattering applied energy to concentrate the applied energyfor interaction with the air stream or to heat the remaining volume ofthe susceptor. Also, a macroscopic artificial dielectric can be madefrom the honeycomb structure by filling some of the cells with anothermaterial. Additionally, a large honeycombed-shaped, macroscopicartificial dielectric structure can be constructed from 1) smallerdiscrete susceptor articles that are small honeycombed shaped articlesthat have differing dielectric properties and/or conductivity or 2)smaller discrete susceptor articles that are honeycombed shaped thathave the same dielectric property and are cemented together with amaterial which has different dielectric properties and/or conductivity.

It is understood by one who reads this that the same or similar methodsused to create honeycombed-shaped macroscopic artificial dielectrics canbe employed to create macroscopic artificial dielectrics out of foamsand weaves.

When the macroscopic artificial dielectric susceptor is designed as adevice with a structure consisting of discrete susceptors, the susceptorcan be designed for complex interaction with the applied energy orenergies as previously described in Example Three. Potentially, eachdiscrete susceptor can have separate characteristics for absorption,transmission, scattering and reflection of 1) applied electromagneticenergy or energies, 2) subsequent fluorescent radiation produced fromthe applied electromagnetic energy or energies, and 3) the subsequentradiation from heat resulting from the dielectric loss within eachindividual susceptor. The discrete susceptors in this invention areknown as unit susceptors. The separate characteristics of absorption,transmission, scattering and reflection of a unit susceptor are effectedby the unit susceptor's length, thickness, shape, composite materialsstructure, material selection, porosity, pore sizes, temperaturedependence of the complex dielectric constant and thermal conductivity.

Since macroscopic artificial dielectric susceptors are made from amixture of unit susceptors, one is capable of designing a variety ofsusceptor structures. The versatility using unit susceptors will beapparent with the following discussion. Although the optical propertiesof each unit susceptor within the macroscopic artificial dielectric canbe independent, the structure of the macroscopic artificial dielectricsusceptor will dictate the interaction of the macroscopic susceptor withthe applied electromagnetic energy. The structure of the macroscopicartificial dielectric susceptor will be described with the unitsusceptors that are primarily reflective. The reflectivity of the unitsusceptors can be produced from either metallic or intermetallicmaterials species at room temperature or materials such assemiconductors, ferroelectrics, ferromagnetics, antiferroelectrics, andantiferromagnetics that become reflective at elevated temperatures. Thematerials that produce reflection can be a) homogeneous, b) compositematerials having a second phase material in a matrix that is partiallyabsorptive to applied electromagnetic energy where the volume fractionof the second phase materials can be used to control the amount ofreflection of a unit susceptor, or c) coatings on a unit susceptor.Also, the length, width and shape of the unit susceptors and thedistance between reflective unit susceptors can be controlled by thereflectivity of the gas-permeable macroscopic susceptor.

The shape of the unit susceptor can be designed for reflection. Theshape of the unit susceptor can be chiral, spire-like, helical,rod-like, acicular, spherical, ellipsoidal, disc-shaped, needle-like,plate-like, irregular-shaped or the shape of spaghetti twist in Muller'sSpaghetti and Creamette brand. The shape of the unit susceptor can bedesigned to produce turbulence in the air flow, thus providing formixing of reactants in the gaseous or liquid stream. The shape and sizeof the susceptor can be used to grade the pore size of the susceptor toaccommodate the expansion of gas due to passing through the hot zone.

The temperature dependent materials that are used in unit susceptors canbe used to produce a temperature self-limiting macroscopic susceptor aswell as to produce in the macroscopic dielectric a desired ratio of aself-limited temperature to power concentration of appliedelectromagnetic energy at one or more frequencies. The above-mentionedstructures can be produced and the desired effects achieved bycontrolling the volume fraction, size and shape of the unit susceptorsand the transmission, reflection, absorption and scattering produced bythe materials selection for each unit susceptor.

The macroscopic artificial dielectric susceptor works on the principleof reflection and diffuse reflection, scattering. The reflectivity ofthe macroscopic artificial dielectric susceptor is controlled by thevolume and interconnectivity of the unit susceptors which are theprimarily reflective unit susceptors in the macroscopic susceptor. Theprimarily reflective unit susceptors are defined as being the unitsusceptors which are primarily reflective to the applied energy orenergies. The gas-permeable artificial dielectric susceptor has theprimarily reflective unit susceptors surrounded by unit susceptors thatare either primarily transparent or primarily absorptive of the appliedenergy or energies. As the volume of the primarily reflective unitsusceptors increases in the macroscopic susceptor, a degree ofinterconnectivity of the primarily reflective unit susceptor will occur,forming an interconnective network within the macroscopic artificialsusceptor. The degree or amount of interconnectivity will depend on thesize and shape of the primarily reflective unit susceptors. The abilityof the applied energy or energies to penetrate the macroscopicartificial dielectric susceptor will depend not only on the volume ofthe primarily reflective unit susceptor but also on the degree andamount of interconnectivity. When the degree of interconnectivity of theprimarily reflective unit susceptors throughout the entire gas-permeablemacroscopic susceptor is such that maximum distance between theinterconnected network of the primarily reflective unit susceptors doesnot allow for applied energy to penetrate or the longest wavelength ofthe applied energies to penetrate, the gas-permeable macroscopicsusceptor, itself, will become primarily reflective to either a) theapplied electromagnetic energy or b) the longest wavelength of theapplied energies. In some instances, a high degree of interconnectivityis desired.

A high degree of interconnectivity can be beneficial in some instances.Clusters of primarily reflective unit susceptors can be distributedabout the macroscopic artificial susceptor to promote scattering.Primarily reflective unit susceptors can be aggregated to form shapesand boundaries that reflect one or more wavelengths of the appliedenergy or energies. The volume fraction and interconnectivity of thereflective unit susceptors surrounding primarily absorbing or primarilytransparent unit susceptors can be used to design specific macroscopicartificial dielectric structures a) for resonant cavities with that arebased upon the wavelength of the applied energy in the susceptor, b) forscattering energy for interaction with gas or particulate species, c)that concentrate energy at field concentrators which are located onother unit susceptors, d) that concentrate energy within the susceptorfor increased reactivity between the gas stream and the fluorescentradiation, e) that have the primarily reflective unit susceptorsarranged in such a manner to produce a large spiral, helical or othershape with the macroscopic susceptor, f) that act as shielding toprevent the applied electromagnetic from entering material inside thecavity for thermal insulation, g) that prevent leakage outside thecavity by the applied energy, h) that reflect applied energy to otherregions of the artificial dielectric to provide either highertemperatures or increased energy for reaction or destruction ofgaseous/particulate species and i) possibly, that regulate thetemperature of the gas-stream.

The several benefits and advantages of this invention compared todevices of prior art will become apparent to one skilled in the art whoreads and understands the following examples of this invention'sempirical results. Table 1 contains data from several gas-permeablemacroscopic artificial dielectrics susceptors that were exposed toapplied electromagnetic energy of a frequency of 2.45 Ghz in thisinvention's cavity as described as having a rectangular cross-sectionalarea perpendicular to the direction of the gas stream's flow. Thelocation of the applied energy's source was as mentioned previously.Each of the following examples of the gas-permeable, macroscopicartificial dielectric susceptor uses unit susceptors.

A type-K thermocouple was inserted into the cavity after the time shown.Prior to inserting the thermocouple, all power to the magnetrons wasturned off. In these examples, the unit susceptors that are designatedas an aluminosilicate (AS) ceramic were made from an 85/15 weightpercent mixture of EPK Kaolin/KT Ball Clay. The unit susceptors that aremade of artificial dielectric materials have an aluminosilicate matrixmade from an 85/15 weight percent mixture of EPK Kaolin/KT Ball Clay.The composition of the unit susceptors that are made from artificialdielectric materials are designate by AS—(volume percent of second phasematerials), i.e. AS-12 SiC. The particle size of each second phasematerial was less then −325 US mesh size. The time to produce a visibleglow—that is, red heat—was observed visually. All examples were separatetests.

The gas permeable macroscopic artificial dielectric susceptor wasexposed to approximately 12.6 KW of power from 16 800-watt magnetrons.The dimensions of the cross-sectional area perpendicular to direction offlow were 7 inches in width and 14 inches in length. The breadth of thecavity was 22 inches. Eight magnetrons were located on each side of theopposite sides of the largest parallel side of the cross-sectional area.On each side, the eight magnetrons were grouped in pairs, and the fourpairs were group one after another along the breadth of the cavity. Inthese examples from experimental results, all unit susceptors are shapedas spaghetti twists (rotini). The spaghetti twists produce a largeamount of free volume within the macroscopic artificial dielectricsusceptor, over 70% free volume.

The result of experiments in these examples show the uniqueness of thisinvention, and the implications of these results that show severaladvantages over the prior art will become clear to the reader afterunderstanding the discussion of the results.

Discussion 1: When the results of Examples 4 and 5 are compared, onefinds that the greater volume percentage of SiC, which makes anartificial dielectric material within the unit susceptors, decreases thetime to show a red glow and increases the temperature after one hour.The macroscopic susceptor of Example 4 is constructed of only unitsusceptors that have a composition of an aluminosilicate ceramic matrixcontaining 6 vol. %−325 mesh SiC, required 51 minutes to show a red glowand after one hour had a center temperature of 803° C., whereas themacroscopic susceptor of Example 5 is constructed of only unitsusceptors that have a composition of an aluminosilicate ceramic matrixcontaining 12 vol. %−325 mesh SiC, required 27 minutes to show a redglow and after one hour had a center temperature of 858° C. In comparingExample 4 with Example 5, one finds that a greater percentage of SiC inthe macroscopic susceptor produced a faster heating rate and a highertemperature the macroscopic susceptor.

TABLE 1 Weight % of each unit susceptor type Time to show Temp. inmacroscopic a red glow after Example susceptor in the device one hourComments 4 100% AS-   51 min  803° C.  6 SiC 5 100% AS-   27 min  858°C.  12 SiC 6 100% AS   29 min >1260° C.   susceptor's temperature exceedthe limit of the type-K thermo- couple 7  50% AS   36 min 1006° C.  50%AS-  12 SiC 8  50% AS   39 min 1008° C. temperature  50% AS- after 3hours  12 SiC 9  50% AS   32 min 1006° C. temperature  50% AS- after 4hours  12 SiC and 30 minutes 10   56% AS    6 min 1142° C.  23% AS-  30Cr₂O₃  12% AS-  30 Chromate  6% AS-  30 Fe₂O₃ and Chromate  3% AS-  30Fe₂O₃ 11   18% AS-  <2 min, had to 2 of the 16  30 Chromate then theshut magnetron  19% AS- glow down tubes melted  30 Cr₂O₃ disappeared.after 30 from the  32% AS- minutes. back  30 Fe₂O₃/ reflection off  30Cr₂O₃ the  9% AS- gas-  30 Chromate/ permeable  30 Fe₂O₃ macroscopic  3%AS- susceptor.  30 Fe₂O₃ Here the  19% AS- large volume  30 CaTiO₃ andhigh degree of interconnec- tivity produced a very reflectivemacroscopic susceptor.

Discussion 2: When the results of Examples 5 and 6 are compared, onefinds that the greater volume percentage of SiC, which makes anartificial dielectric material within the unit susceptors, does notgreatly effect the time to show a red glow and decreases the temperatureafter one hour when compared to unit susceptors that are just made fromthe aluminosilicate ceramic matrix material. The macroscopic susceptorof Example 6 is constructed of only unit susceptors that have acomposition of an aluminosilicate ceramic matrix containing 12 vol.%−325 mesh SiC, required 27 minutes to show a red glow and after onehour had a center temperature of 858° C., whereas the macroscopicsusceptor of Example 6 is constructed of only unit susceptors that havea composition of the aluminosilicate ceramic matrix contain 0 vol. %−325mesh SiC, required 29 minutes to show a red glow and after one hour hada center temperature that was greater than 1260° C. In comparing Example5 with Example 6, one finds that the 12 vol. % of SiC in the macroscopicsusceptor of Example 5 suppresses the temperature of the macroscopicsusceptor as compared to the macroscopic susceptor that was constructedof unit susceptors that are constructed of the aluminosilicate matrixalone.

Comparison between Discussion 1 and Discussion 2: In Discussion 1, theincreased volume percentage of SiC in the unit susceptors, which areconstructed of an artificial dielectric material, shows that the greatervolume of SiC in an artificial dielectric material increased theabsorption of the applied electromagnetic energy; the heating rate andtemperature after one hour increased. In Discussion 2, the resultsshowed that the macroscopic susceptor without the artificial dielectricmaterial, (AS-vol. % SiC), had a) about the same heating rate as theartificial dielectric material with 12 vol. % SiC and b) a highertemperature than the artificial dielectric material with 12 vol. % SiC.One can understand that the greater SiC content in the artificialmaterial in Example 5 compared to Example 4, increases the absorption ofmacroscopic susceptors.

One can also understand that when one compares Example 5 to Example 6,one finds that the absorption of the applied energy by the unitsusceptor, which is made of an artificial dielectric material,suppresses the temperature after one hour. This suppression of thetemperature can be due to the reflectivity of the SiC as the temperatureof the SiC increases.

Discussion 3: When one compares Example 7 with Example 4, one findsintriguing results. Example 7 uses a macroscopic artificial dielectricsusceptor made from a 50/50 mixture of two types of unit susceptors. Onetype of unit susceptor is the primarily reflective and is constructed ofan artificial dielectric material, AS-12 SiC, the material used inExample 5. The other type of unit susceptors is the primarily absorptiveunit susceptor material and is constructed of the AS material that wasused in Example 6. The 50/50 mixture of the two types of unit susceptorsdid not produce an interconnective network between the primarilyreflective unit susceptors. When one carefully compares the results fromExample 4 and Example 7, one finds that the total amount of SiC on themacroscopic susceptor for the unit susceptor that is constructed of theartificial material, AS-6SiC in Example 4 is approximately equal to thetotal volume of SiC in the macroscopic artificial dielectric susceptorin Example 7. In Example 7, the 50/50 mixture of the AS unit susceptorsand the AS-12 vol. % unit susceptors produces approximately the samevolume of SiC in the macroscopic susceptor as Example 4. However,Example 7 has faster time to show a red glow then Example 4 and a highertemperature after one hour (1006° C.). Absorption by the total volume ofSiC in the macroscopic susceptor cannot be fully responsible for theresults in Example 7. It is the structure, the macroscopic artificialdielectric susceptor, that is responsible for the increased time to showa red glow and a higher temperature after one hour (1006° C.).Therefore, the structure of the macroscopic artificial dielectricsusceptor that contains the primarily reflective unit susceptors thatare mixed with the primarily absorptive susceptors, must be having theprimarily reflective unit susceptors reflecting, or scattering theapplied energy and the scattered (reflected) energy is being absorbed bythe primarily absorptive unit susceptors. The primarily reflective unitsusceptors are concentrating the energy within the macroscopicartificial dielectric susceptor.

Discussion 4: When one compares the results from Examples 7, 8 and 9,one finds that the macroscopic artificial dielectric structure canproduce a self-limiting temperature, and since it can produce aself-limiting temperature, the gas-permeable macroscopic artificialdielectric structure should allow one to design macroscopic artificialdielectric structures to a desired self-limiting temperature to powerconcentration of applied energy or energies to heat gases and to reactchemical species in a gas stream.

Discussion 5: The results of Example 10 show an effect one finds whenthe gas-permeable macroscopic artificial dielectric susceptor isconstructed of primarily reflective unit susceptors which are made froman artificial dielectric material that contains a greater volumepercentage of semi-conducting and materials with a Curie temperature.The primary reflective unit susceptors were constructed of an artificialdielectric containing 30 vol. % of -325 mesh materials that were eitherCr₂O₃, Fe₂O₃, chromate or a mixture containing two of the threematerials. The matrix of the artificial dielectric material was the ASmaterials. The gas-permeable artificial dielectric that was constructedfrom these primarily reflective unit susceptors had a very fast time toshow a red glow and a high temperature (1142° C.). Example 10 shows thatthe amount of reflection of the primarily reflective susceptorsinfluences the heat rate of, temperature of and energy concentrationwithin the macroscopic artificial dielectric susceptor. One canunderstand that the amount of reflection also should allow one to designmacroscopic artificial dielectric structures to a desired self-limitingtemperature to power concentration of applied energy or energies to heatgases and to react chemical species in a gas stream as well as willincrease the energy concentration within the artificial dielectricsusceptor.

Discussion 6: Example 11 exemplifies what happens when the volumefraction and the interconnectivity of the primarily unit reflectivesusceptors become too great. At first one sees that a very fast time toshow a red glow red is present, then the glow disappears. What hashappened in this example is that the temperature of the primarilyreflective unit susceptors increased by absorbing the applied energy,and then the increased temperature caused the primarily reflective unitsusceptors either to have Curie temperature to be exceeded, to havegreater reflectivity or both in the unit susceptors' materials ofconstruction. With the increase reflectivity, Curie temperatureexceeded, high volume fraction of the primarily reflective unitsusceptor and extremely high degree of interconnectivity of theprimarily reflective unit susceptors, the macroscopic artificialdielectric susceptor became reflective and did not allow for the appliedenergy to volumetrically interact with the macroscopic artificialdielectric susceptor. The back reflection from the macroscopicartificial dielectric susceptor destroyed two microwave tubes.

Of importance is the structure of a macroscopic artificial dielectricsusceptor. The structure should allow for applied electromagnetic energyto penetrate the distance between the primarily reflective components,whether a discrete susceptor, coating or woven structure so thestructure does not act as a collection of waveguides with cut-offfrequencies that prevent the applied energy from penetrating the widthof interaction.

Another aspect of this invention is the use of the structure of themacroscopic artificial dielectric susceptor for adsorption, regenerationand desorption of gaseous reactants. The structure can be used with suchdevices as rotary concentrators or other devices that use adsorption ina process to treat to pollutants. Typically in such devices, a zeolitematerial or activated carbon is used to adsorb gaseous species. Otherforms of carbon also can be used. The penetration depth of carbon in theform of an article tends to be about one micron, and in loose powder,the penetration depth can be 3 mm. Zeolite materials, depending upontheir doping, have much greater penetration depths.

A macroscopic artificial dielectric susceptor can be made from a mixtureof unit susceptors. The mixture would contain unit susceptors made withactivated carbon and unit susceptors made with zeolites. Also, unitsusceptors can be made from either a) artificial dielectric materialshaving a zeolite as the matrix and a carbon species as the second phase,b) artificial dielectric materials having a carbon species as the matrixand zeolite species as the second phase, or c) unit susceptors that arecoated with a carbon species, preferably activated carbon. As in thekeeping with the aspects of this invention, the structure of amacroscopic artificial dielectric susceptor should allow for appliedelectromagnetic energy to penetrate the distance between the primarilyreflective components, whether a discrete susceptor, coating or wovenstructure so that the structure does not act as a collection ofwaveguides with cut-off frequencies that prevent the applied energy frompenetrating the width of interaction.

Another aspect of this invention is the use of semi-conducting metalsand ceramics, ionic-conducting ceramics, ferromagnetic, ferrimagnetic,ferroelectric and antiferroelectric materials for their reflectivecharacteristics of the applied electromagnetic energy. These types ofmaterials tends to be primarily absorbing materials as articles or largeparticles (particle sizes greater than 250 microns), however when theparticle size of these types of materials are 50 microns or less thesesemi-conducing materials greatly absorb the applied energy, especiallywavelengths in the microwave region, and reach very high temperatures,becoming very conductive. When these materials become very conductive athigh temperatures, they become very reflective. Reflective behavior fromthe small particle-size SiC in the unit susceptors that were constructedof artificial dielectric materials, not the volume fraction of the SiC,is the only way to explain the different behavior between Example 4,Example 5 and Example 7. In this invention, SiC is used as a hightemperature reflector.

The conductivity of these types of materials as well as other ceramicmaterials, mentioned above can be controlled by caption and anionsubstitution on the lattice structure of the materials. Typically, theamount of substitution of caption or anion on a lattice structure of amaterial would be less than 15 mole percent.

The absorption, transmission, reflection, scattering and the complexdielectric constant of unit susceptors can be controlled by usingcomposite materials. These composite materials are artificialdielectrics, layered or coated composites, having a matrix materialcontaining a second phase or third phase which has a particle diameterless than −325 US mesh size. The composite materials for unit susceptorscan use combination of materials in such a fashion where the matrix isa) a metal forming a cermet, b) polymeric organic materials, c) apolycrystalline ceramic, d) a glass/ceramic material, and e)intermetallic. Materials for the matrix, substrate for a coated unitsusceptor or entire unit susceptor include a) aluminosilicates andsilica derived from clays or mixture of clays, b) alumina, c) MgO, d)stabilized and partially stabilized zirconia, e) magnesium silicates andsilica derived from talcs, f) enstatite, g) forsterite, h) steatite, i)porcelain ceramics, j) cordierite, k) fused silica, l) stainless steel,and m) cast iron. The second phase materials can be 1) athermoluminescent material, 2) a phosphorescent material, 3) anincandescent material, 4) ferroelectric, 5) ferromagnetic, 6)ferrimagnetic, 7) MnO₂, 8) TiO₂, 9) CuO, 10) NiO, 11) Fe₂O₃, 12) Cr₂O₃,13) Li₂O doped MnO₂, 14) Li₂O doped CuO, 15) Li₂O doped NiO, 16)CuO—MnO₂—Li₂O complex, 17) CuO—MnO₂, 18) silicide, 19) borides, 20)aluminides, 21) nitrides, 22) carbides, 23) ceramic glazes with metalparticles, and 24) ceramic glazes with semi-conducting particles. Theshape of the second phase materials can be chiral, spire-like, helical,rod-like, acicular, spherical, ellipsoidal, disc-shaped,irregular-shape, plate-like or needle-like.

Another aspect of this invention is a conceptual design of the structureof a unit susceptor's artificial dielectric material that increases thechemical compatibility between the matrix and second phase material. Thesize of the second phase material can be used to control the chemicalcompatibility between the matrix and the second phase material. Largerparticle sizes of the second phase material will make the second phasematerials more compatible with the matrix. In this invention, where thesecond phase material has questionable compatibility with the matrix thesecond phase material is to have a particle size between 200 microns and4 mm. Chemical incompatibility can lend to melting or other solid-statereactions at the interface between the matrix and the second phasematerial. The melting and solid-state reactions can lead to greaterabsorption, and possible to a situation that leads to thermal runaway inthe material.

Another aspect of this invention is the design of unit susceptors thathave artificial dielectric materials that have compatible thermalexpansions between the matrix and the second phase material. Poorthermal expansion compatibility can lead to friable unit susceptors fromthermally cycling the device during operation. The two methods that thisdevice uses are a) materials where the thermal expansion mismatch isless than 15% and b) the matrix and the second phase material has thesame lattice structure and principle composition, but the latticestructure of the second phase material is doped with a cation or ananion to change the electrical resistance of the second phase materialin the artificial dielectric material. Using the spinel structure asexamples, the matrix material can be MgAl₂O₄ and the second phasematerial would be (Mg,Fe)Al₂O₄, and the matrix of Fe₂O₃ and the secondphase material is Fe₂O₃ doped with TiO₂. Additionally, the matrix can beAlN and the second phase materials can be AlN doped with Fe⁺³.

The thermal conductivity of the unit susceptor can be controlled forheat transfer. The thermal conductivity can be controlled by either a)porosity of the material of the unit susceptor, b) the compositestructure of the unit susceptor, c) high thermally conductive materialssuch as from high purity nitrides, aluminides, silicides, borides andcarbides, d) highly thermally conductive coatings can be used as coatingon porous unit susceptors to increase the thermal conductivity at thesurface, or e) grading the pore structure by flame polishing the outersurface of the susceptor.

Another aspect of this invention is the use of unit susceptors orcoatings on unit susceptors that are sacrificial. The sacrificialsusceptors or coatings are used in chemical reactions. For example, toeliminate NOx from gas streams, NOx can be reacted with carbon toproduce N₂ and CO₂. In this example carbon is needed as a reactant.Therefore, unit susceptors or coating on unit susceptors could be madewith carbon that is sacrificial. After the carbon-containing unitsusceptors are used up, the macroscopic artificial dielectric structurecan be replenished with the new carbon-containing susceptors. The formof carbon can be activated carbon, carbon black, soot, pitch, orgraphite.

Another aspect of this invention is the use of field concentrators onthe surface of the unit susceptors. The field concentrators concentratethe electromagnetic field locally so a high intensity electromagneticfield is available to interact with gaseous/particulate species toeither drive chemical reaction, enhance the reaction between chemicalspecies or to treat pollutants. The field concentrator would be madefrom either a) conductors, b) semi-conductors, c) materials with a Curiepoint, d) ionic-conducting ceramic, e) composite materials from a and c,f) composite materials from b and c, g) composite materials from a andd, and h) composite materials from b and d. The shape of the compositematerials can be chiral, spire-like, helical, rod-like, acicular,spherical, ellipsoidal, disc-shaped, irregular-shape, plate-like,needle-like or have a shape that has sharp-pointed-gear-like teeth. Thesize of the field concentrators can be one to 10 times the depth ofpenetration of applied electromagnetic energy of material construction,either at room temperature or the operating temperature. This sizedifference depends on the chemical compatibility between the fieldconcentrators and the unit susceptor's materials of construction. Wherethere is little concern for deleterious reaction between the unitsusceptor and field concentrator, then the size of the fieldconcentrator, which, based on its depth of penetration of the materialsof construction, can be 1 to 10 times the depth penetration at theoperating temperature. If there is great concern for deleteriousreaction between the unit susceptor and field concentrator, then thesize of the field concentrator should be such not to promote reaction,200 microns to 4 mm.

Additionally, a barrier coating between the field concentrator and theunit susceptor can be present to prevent deleterious chemical reactionbetween the field concentrator and the unit susceptor. Materials forfield concentrators include materials that can be 1) a thermoluminescentmaterial, 2) a phosphorescent material, 3) an incandescent material, 4)ferroelectric, 5) ferromagnetic, 6) ferrimagnetic, 7) MnO₂, 8) TiO₂, 9)CuO, 10) NiO, 11) Fe₂O₃, 12) Cr₂O₃, 13) Li₂O doped MnO₂, 14) Li₂O dopedCuO, 15) Li₂O doped NiO, 16) CuO—MnO₂—Li₂O complex, 17) CuO—MnO₂, 18)silicide, 19) borides, 20) aluminides, 21) nitrides, 22) carbides, 23)ceramic glazes with metal particles, 24) ceramic glazes withsemiconducting particles, 25) materials that produce thermionicemissions, and 26) thermoelectric materials.

Another aspect of this invention is the production of ozone from unitsusceptors and field concentrators. When the distance (gap) between twoconducting or semiconducting field concentrator becomes close enough tocause a discharge of a spark for the field that is produced by theapplied electromagnetic energy, ozone will be produced. The same type ofdischarge can occur on the surface of unit susceptors that areconstructed of an artificial dielectric material. A spark can occur fromgap between the exposed surfaces of the second phase material in theartificial dielectric, and ozone can be produced. This can occur atelevated temperature and when the volume fraction of the second phasematerial exceeds twenty percent (20%). Also, an electric discharge canoccur between two unit susceptors that contain field concentrators andthe gap between exposed surfaces of second phase material from two unitsusceptors.

Another embodiment of this invention is a heat transfer process. Theinvention embodies the input chemical species flow obtaining heat, orbeing preheated, prior to entering the device for thermal or othermethods of treatment by a heat exchange method that provides heat to theinput chemical species flow from heat that is produced from the sourcefor applied energy. The source can be any device that produces theapplied energy. Such a device generally operates at low efficiencies andproduces heat. This heat transfer process for preheating the inputchemical species flow will decrease the cost of operating such a device.The heat from the tube, or tubes, can be exchanged with the inputchemical species flow. After the input chemical species flow ispreheated with heat from the tube, the input chemical species flow canbe further heated by heat transfer either a) from the cavity walls, b)from a conventional heat exchanger (a recuperator) which is locatedafter the exit end of the device, or c) from both the cavity walls andconventional recuperator.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-section of the device according to the invention in alongitudinal axial direction of the breadth of the device and width ofthe device.

FIG. 2 is the device as in FIG. 1 with thermally insulating layers.

FIG. 3 is a cross-section of the device normal to the direction of Flowwith relationship between the susceptor 9 and the depth of penetrationof the susceptor 14.

FIG. 4 is a flow chart representing a heat transfer process.

FIG. 5 is a 2-dimensional graphical representation of the gas-permeable,macroscopic artificial dielectric susceptor that is constructed ofobjects representing unit susceptors where one type of unit susceptor isprimarily reflective and the other type of unit susceptor is eitherprimarily transparent or partially absorptive.

FIG. 6 is a 2-dimensional graphical representation of the gas-permeable,macroscopic artificial dielectric susceptor which is constructed ofobjects representing unit susceptors that have an interconnected networkof primarily reflective unit susceptors.

FIG. 7 is a unit susceptor that is constructed of an artificialdielectric material.

FIG. 8 illustrates field concentrators on the unit susceptors.

FIG. 9 illustrates field concentrators on the surface of, embedded inthe surface of, and embedded within the unit susceptors.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This invention is a useful energy product created by a process where achemical species flow passes through a macroscopic artificial dielectricstructure for a gas-permeable susceptor consisting of first regions inthe structure that are primarily transparent to applied electromagneticenergy and second regions in the structure that are not primarilytransparent to applied electromagnetic energy. This invention is adevice that uses a gas-permeable structure for a susceptor ofelectromagnetic energy to react gases for desired products. The devicehas a specific cavity geometry, location where the applied energy from asource enters the cavity, a susceptor that is designed by the depth ofpenetration of the susceptor, and a means to scale-up the device forlarger flow rates of an air stream without changing the susceptor'sinteraction with the applied energy or depth of penetration of thesusceptor because the device is designed to increase the size of thedevice by a near linear scale from the location where the appliedelectromagnetic energy enters the cavity and the cavity's geometry.

Another aspect of this invention is a heat transfer process thatincreases the efficiency of the device.

Another aspect of this invention is a gas-permeable, macroscopicartificial dielectric susceptor which uses reflection, scattering andconcentration of the applied electromagnetic energy which is used a) toreact gases for desired products, b) to regulate the temperature of theair stream, c) to prevent the device from overheating, d) to preventdeleterious reactions between the materials of construction, e) to heata gas stream, f) to create a device of substantial size for adsorptionand regeneration of gaseous species from a mixture of carbon-containingsusceptor and zeolite-containing susceptors, and g) to produce a desiredratio of a self-limited temperature to power concentration of appliedenergy or energies to perform the desired utility.

Another aspect of this invention is the structure of the unitsusceptors, which can make up the gas-permeable, macroscopic artificialdielectric susceptor.

Another aspect of this invention is the use of field concentrators onunit susceptors to create local electromagnetic fields by interactionwith the applied electromagnetic energy.

The integral parts of the device are the cavity 1, the inlet opening 2,which is permeable to gases and particulate and provides a means toprevent applied electromagnetic energy from escaping the cavity, theoutlet opening 3, which is permeable to gases and provides a means toprevent applied electromagnetic energy from escaping the cavity, openingto the cavity 4, which allows the applied electromagnetic energy toenter the cavity, lenses 5, which focus or disperse the appliedelectromagnetic energy in the cavity, and if necessary, provide agas-tight seal to prevent gases and particulate from escaping thecavity, applied energy 6, electromagnetic energy sources 7, waveguides8, and susceptor 9, which is the suscepting region on the device.

Discussion of FIGS. 1, 2 and 3 illustrates the construction of thedevice to react gases for desired products, details the operation forthe device and discloses, in its broadest sense, the primary embodimentof this invention.

FIG. 1 is an axial, longitudinal section of the device that is known inthis invention as the device breadth. In FIG. 1, the geometric axes ofthe device are given by arrows marked W for width and B for breadth. Thedevice has a rectangular cavity 1, having an inlet opening 2 wherereactant gases or pollutants enter the cavity. Inlet opening 2 isdesigned to be permeable to reactant chemical species, gases, andparticulate, all termed chemical species herein, in the air stream. Thereactant chemical species enter cavity 1 though inlet opening 2, andenter susceptor 9. As the chemical species pass through susceptor 9,chemical species are converted to products, specifically a useful energyproduct, by the necessary treatment means which are produced from theinteraction of applied electromagnetic energy 6 with susceptor 9. Theproducts exit cavity 1 though outlet opening 3. The interaction betweenapplied energy 6 and susceptor 9 can provide treatment means either a)by a primarily thermal method having all or a very large amount theapplied electromagnetic energy 6 being absorbed and producing heat insusceptor 9, b) by a method having the electromagnetic energy primarilyinteract with the gas reactants, pollutants and particulates without asubstantial quantity of applied energy 6 absorbed by susceptor 9,producing heat, c) by a method having a combination of methods a and b,or d) by a method where the combined effects of method c and othersubsequent fluorescent radiation, thermoluminescent radiation,thermionic emission and thermoelectricity assist in treating the gasreactants, pollutants and particulates.

The method of treatment is determined by the interaction of appliedelectromagnetic energy 6 with the material or materials of constructionthat make-up the susceptor 9. The applied electromagnetic energy 6 canbe of more than one frequency, UV, IR, visible and microwave. Theapplied electromagnetic energy 6 enters cavity 1 through openings 4 thatare located on opposing sides of the cavity 1, as shown in FIGS. 1, 2and 3. The applied electromagnetic energy 6 is generated fromelectromagnetic sources 7, travels down waveguides 8, and can passthrough lenses 5, which can be located at cavity opening 4, theninteracts with the susceptor 9. If lenses 5 are not needed for theoperating conditions of the device, then the applied electromagneticenergy 6 can just enter cavity 1 through cavity openings 4.

The chemical species enter through inlet opening 2 and enter susceptor 9for treatment. Turbulence can be generated by the structure of susceptor9 to provide better mixing. The residence time in the device that isrequired by a specific treatment method is provided by increasing thebreadth of the device, which is inclusive of increasing the breadth ofsusceptor 9 and cavity 1. Additionally energy sources 7, waveguides 8,and cavity openings 4, can be arranged along the breadth of the deviceto provide the necessary power of applied energy to the susceptor fortreatment. Such additionally energy sources 7, waveguides 8, and cavityopenings 4 on opposing faces can be arranged by anyone skilled in theart to provide the optimum conditions. Electronic methods of controllingapplied power and start-up methods can be employed by those skilled inthe art without taking away from the embodiment of this invention. Thisdevice can be employed in operation in a horizontal position and/or in avertical position.

FIG. 2 provides the same view as FIG. 1. FIG. 2 illustrates the locationof thermal insulation 10 and a thin thermally insulating barrier 11 thatprevents gases, pollutants and particulates from passing through itsboundaries. Thermal insulation 10 and a thin thermally insulatingbarrier 11 surround the perimeter of susceptor 9 in the direction of thebreadth of the susceptor. Thermal insulation 10 and thin thermallyinsulating barrier 11 is constructed of material that is transparent tothe applied electromagnetic energy. Material of construction that aretransparent to the applied electromagnetic energy can be high purityalumina, aluminosilicate, MgO, steatite, enstatite, fosterite, nitrides,ceramic porcelain, fused silicate and glass in fiber or foam form. Thepreferred materials structure for thermal insulation 10 is an aerogel.The thermally insulating layer 10 and thin thermally insulating barrier11 are employed to prevent cavity 1 and waveguides 8 and energy sources7 from being effected in an adverse manner by heat from treatmentmethods which can cause unwanted thermal expansion, corrosion anddeterioration of electronic.

FIG. 3 is a cross-section of the device that is normal to the directionof gas flow from inlet 2 to outlet 3. The directional axes for thediscussion of the embodiments of the device are show in FIG. 3 andlabeled W for width and L for length. The device in this inventionembodies the geometric shape of the cavity's cross-section that isnormal to the direction of airflow 14 in cavity 1, the location ofopenings 4 in cavity 1, the depth of penetration of the susceptor 13,and the width of interaction 12. The geometric shape of the cavity'scross-section that is normal to the direction of flow 14 is an irregularshaped polygon that has the largest dimension of the two parallel sidesas it length. The preferred irregular-polygon has four (4) sides and isa rectangle as shown in FIG. 3. This embodiment is not limit to anirregular-shaped polygon with 4 sides, the irregular-shaped polygon musthave a minimum of four (4) sides.

This invention embodies the geometric shape of the susceptor'scross-sectional area that is normal to the direction of flow ofsusceptor 9 to have the same geometric shape of the cavity'scross-sectional area that is normal to the direction of flow 14. Thisinvention embodies the location of the openings 4 in cavity 1 to belocated on opposing sides of longest parallel direction of the cavity'scross-section that is normal to the direction of flow 14, which istermed the length of cross-section 14.

The susceptor 9 in this invention embodies a design to have volumetricinteraction with the electromagnetic energy. Susceptor 9 is designed tohave a depth of penetration of the susceptor 13 by appliedelectromagnetic energy 6 at the operating temperature that can not beless then one-third (⅓) the width of the of susceptor. This embodieddesign allows for a minimum 50% of the applied electromagnetic energy 6to be present in each half volume of the susceptor 9, where the halfvolume of the susceptor 9 is defined by the product of the width ofinteraction 12 by the length of the susceptor by the breadth of thesusceptor 9. The width of interaction is equal to one-half of the widthof the interior dimensions of cavity 1. The embodied susceptor designallows a) for volumetric interaction between the applied energy 6 andthe susceptor 9 and b) for volumetric interaction between applied energy6 and the reactant gases, pollutants and particulates. The rectangularcavity design does not concentrate energy by the geometry of therectangular cavity 1 or the rectangular shape of the susceptor. Providedthat the susceptor is a homogeneous material, the rectangular shape ofthe susceptor interacts optically with the applied electromagneticenergy 6 from openings 4 in cavity 1 as though the susceptor was a flatlens. On the other hand, if the geometry of the cavity's cross-sectionalarea normal to the direction of flow and geometry of the susceptor'scross-sectional area normal to the direction of flow was circular andthe applied energy enters this type of cavity from openings that werelocated around the perimeter of the cavity, then applied energy willtend to concentrate in the circular susceptor.

The device, in this invention, embodies the ability to linearly scalethe device for chemical species streams with larger flow rates withouthaving to redesign the depth of penetration of the susceptor 13. Thelinear scale is accomplished simply by keeping the widths of susceptor 9and of cavity 1, while extending the lengths of the susceptor 9 andcavity 1. The depth of penetration of the susceptor 13 and the width ofinteraction 12 will remain constant. One may have to add more energysources 7, waveguides 8, and/or openings 4, in cavity 1 along theextended length to provide more power to the cavity, but the costinvolved is much less than redesigning the susceptor's properties thatinteract with the applied electromagnetic energy to provide volumetricinteraction between the applied energy and the susceptor's and cavity'snew size and geometric structure. Additionally, the cost to treat higherflow rates in the same size cavity as lower flow rates by increasing thepower can require the use of costly high power tubes that produce theelectromagnetic energy.

Another aspect of the invention, as shown in FIG. 3, is employingwaveguides 8 that intersect the surfaces of the cavity 1 at obliqueangles to produce large openings 4 in cavity 1 that allow for theapplied electromagnetic energy 4 to be applied over a larger surface ofthe susceptor. Also, the use of waveguides 8 allows for the energysource 7 to be located away from the cavity to lessen any deleteriousinteraction between heat and the energy source 7.

The dimensions of the cavity 1 can be designed for the frequency of theapplied electromagnetic energy and the TE and TM modes of the appliedelectromagnetic energy. The size of the cavity 1 may be adjusted toaccommodate desired TE and TM modes at certain power levels, whichproduce more uniform heating of the susceptor.

The inlet 2 and outlet 3 can prevent the applied electromagnetic energy6 from escaping with a perforated article made from a reflectiveartificial dielectric materials, polarizers that are arranged in across-nickels fashion, fermi-cages, attenuators, or undulating paths.

The thickness of the wall in cavity 1 is determined by the skin depth ofthe material for the applied frequency or frequencies. The thickness ofthe wall is a minimum three (3) skin depths of the material for theapplied frequency. When more than one frequency of electromagneticenergy is applied to the cavity 1, the skin depth of materials isdetermined by the lowest frequency of radiation.

The materials of construction that are selected for the cavity 1 isdependent on operating temperatures. The materials can be stainlesssteels, aluminum, aluminum alloy, nickel, nickel alloy, inconel,tungsten, tungsten alloys, aluminides, silicides, vanadium alloys,ferritic steel, graphite, molybdenum, titanium, titanium alloys,artificial dielectric materials which are design to reflect incidentradiation, copper alloys, niobium alloys, chromium alloy, inconel,chromyl, alumel, copper/constantine alloys and other high temperaturealloys. For radio frequencies, transparent materials such as aluminaporcelains, zircon porcelains, lithia porcelains, high temperatureporcelains, glasses, alumina, mullite, fused silica, quartz, forsterite,steatite, cordierite, enstatite, BN, AlN, Si₃N₄, oxides and otherpolymers which exhibit low dielectric and conductive losses at theapplied frequencies can be applied.

The applied electromagnetic energy at one or more frequencies can enterthe cavity through openings 4 in the walls adjacent to the macroscopicsusceptor or be channeled through the cavity to the macroscopicsusceptor from either above, below or passing through transparentthermal insulation adjacent to the side walls. The applied energy canenter through a single or plural openings that either contains insertedbulbs, antenna or tubes, that are either couplers, lenses, slottedwaveguide or zigzag slotted waveguides. The applied energy 6 can belinearly polarized, circularly polarized or polarized by reflection orscattering. Entering radiation from multiple couples can be polarized insuch a manner to achieve a better distribution of electromagnetic energyin the cavity.

More than one frequency of electromagnetic energy can be propagatedthrough the openings 4. For waveguides 8, the cut-off frequency willdetermine the frequencies that can propagate through the waveguide.

When lenses 5 are employed, optical engineering for the lenses can beused to obtain the desired effect. The radius of curvature of the lensor lenses can be adjusted to concentrate or disperse the electromagneticenergy (convergence and divergence of the applied energy). The lensthickness can be adjusted to eliminate or greatly reduce reflection ofthe energy so that the reflection of the energy back to the radiationsource does not damage the source. Coatings on the lenses can be use toreflect selected wavelengths back into the cavity. Materials for lenses5 should have high purity (greater than 99% pure) transparent singlecrystals, polycrystalline and amorphous organic and inorganic materialswith low dielectric constants, low dielectric losses such as aluminaporcelains, zircon porcelains, lithia porcelains, high temperatureporcelains, glasses, alumina, mullite, forsterite, steatite, cordierite,enstatite, BN, AlN, Si₃N₄, oxides and other polymers, MgO, fused silica,iodides, bromides, polycarbonate, polypropylene, and quartz. Theporosity of the material can be used to scatter the applied energy intothe cavity. The porosity would be designed for the applied energy.

Waveguides 8 can either be horns or rectangular, cylindrical, orparabolic shapes. The best waveguide shape is a rectangle thatintercepts the surface of the cavity at oblique angles as shown in FIG.3. The oblique angle increases cross-sectional area of the opening intothe cavity and minimizes the back reflection off the surface of themacroscopic susceptor and/or insulation into the waveguide which wouldbe transmitted back to the radiation source 7 or diminish the power 6emanating from the waveguides 8.

Another embodiment of this invention is a heat transfer process. Theheat transfer process is illustrated by the flow chart in FIG. 4. Theinvention embodies the input chemical species flow obtaining heat, orbeing preheated, prior to entering the device for thermal or othermethods of treatment by a heat exchange method that provides heat to theinput chemical species flow from heat that is produced from the sourcefor applied energy. The source can be a magnetron, a UV lamp, an IR lampor other electronic device that produces the applied energy 6. Such adevice generally operates at low efficiencies and produces heat. Thisheat transfer process for preheating the input chemical species flowwill decrease the cost of operating such a device. The heat from thetube, or tubes, can be exchange with the input chemical species flow bysuch cooling fins, such as those that are found on commercialmagnetrons, heat pipes, thermoelectric devices, cooling systems thatcirculate a fluid around the tube or lamp and release the heat at aradiator. After the input chemical species flow is preheated with heatfrom the tube, the input chemical species flow can be further heated byheat transfer either a) from the cavity walls, b) from a conventionalheat exchanger (a recuperator) that is located after the exit end of thedevice, or c) from both the cavity walls and conventional recuperator.

Heat exchange with the artificial dielectric device and other devicesthat use electromagnetic energy can allow for increased energyefficiency of the device, as well as to allow for increased energyefficiency to processes outside the device in an industrial process orwithin a manufacturing facility. Increased energy efficiency of thedevice reduces the operating cost of the device, while the increasedenergy efficiency outside the device utilizes heat energy produced bythe device for other applications. These applications can be, but arenot limited to, heating water for washing applications in textileoperations, heating water for pulping operations, preheating air forcombustion in coal-fired electricity generation, preheating air, methaneor both for gas-fired turbine electricity generation, preheating ammoniafor selective non-catalytic reduction (SNCR) of nitrogen oxides (NOx)and selective catalytic reduction (SCR) or nitrogen oxides (NOx) and topreheat methane or other gaseous organics prior to entering a devicewhich catalyzes the methane or other gaseous organic species to higherorder molecules.

The heat exchange process in FIG. 4 can have additional steps. Thesesteps can include additional heat exchange, cooling of the outputchemical species flow prior to heat exchange with either a conventionalheat exchanger, charged air cooler, heat pipes or other device, andmixing input chemical species flow from different heat exchange methodsprior to entering the device which treats the input chemical speciesflow.

Another aspect of this invention is a heat exchange process having thesteps where: step (1) the heat exchange between the source ofelectromagnetic energy and the input chemical species flow or part ofthe input chemical species flow occurs; step (1 a) next the inputchemical species flow or part of the input chemical species flow isfurther heated by heat exchange between the exiting hot, output chemicalspecies flow by exchange of heat with either conventional pipe heatexchanger, heat pipes, charged air coolers or other means; step (2) thenthe input chemical species flow or part of the input chemical speciesflow enters the device to be treated; and step (3) output chemicalspecies flow exits the device and exhausts through the heat exchangesystem. The benefits of this method for a heat exchange process is thatthe experimentally measured temperatures of cooling air over magnetrons,at steady-state conditions in this device and under the operatingconditions, provide data that exhibits a temperature change of theambient air after exchanging heat with the magnetron tubes. The initialambient air temperature of approximately 80° F. was raised toapproximately 130° F., providing a change in temperature ofapproximately +50° F. This small, but significant, rise in airtemperature provides cooling for the electromagnetic source, magnetrons.Without this cooling, the magnetrons would overheat, reduce their poweroutput, lessen the lifetime of electronic device or combination thereof.This heat exchange process must be carried out in the order of step (1)then step (1 a). This process cannot exchange the order of step (1) andstep (1 a) and provide the necessary cooling of the electromagneticsource. If step (1 a) was switched with step (1), then the gases leavingthe heat exchange method in step (1 a) would be too hot to provide thenecessary heat exchange for cooling the electromagnetic source.

Other experimental data provides support for the order of the steps. Thetemperature of the output chemical species flow, under operatingconditions and prior to exhausting via the heat exchanger in step (1 a),was in excess of 842° F. The heat exchange from step (1 a) would raisethe temperature of the input gases too great to be effective in coolingthe applied electromagnetic source. Even if the gaseous output chemicalspecies are expanded to reduce the temperature of the output chemicalspecies flow prior to entering the heat exchanger in step (1 a), it isdoubtful that an effective heat exchange process and desired massbalance between the input chemical species flow and the output chemicalspecies flow could be obtained.

Another aspect of this invention is a heat exchange process having thesteps where: step (1) the heat exchanges between the source ofelectromagnetic energy and the input chemical species flow or part ofthe input chemical species flow occurs; step (1 a) next the inputchemical species flow or part of the input chemical species flow isfurther heated by heat exchange between the exiting hot, output-chemicalspecies flow by exchange of heat with either conventional pipe heatexchanger, heat pipes, charged air coolers or other means; step (2) thenthe input chemical species flow or part of the input chemical speciesflow enters the device to be treated; step (3 a) output chemical speciesflow exits the device and the output chemical species flow is cooled;and step (3 b) the output chemical species flow exhausts through theheat exchange system. In step (3 a) the output chemical species flow canbe cooled by a variety of means and for a variety of purposes. Coolingin step (3 a) can occur by expanding the gaseous output chemicalspecies, using a coil containing fluid species that is in communicationwith neither the input nor the output chemical species or other methods.Step (3 a) provides for the use of lower cost material for theconstruction of the heat exchange devices in step (1 a). These materialscan be aluminum, aluminum alloys, or other. In addition, step (3 a)allows for the application of the heat exchange process with thetreatment device to be optimized for economic benefit of an industrialprocess or manufacturing facility. Examples of potential economicbenefit are: textiles industry—an economic benefit to cool the outputchemical species in step (3 a) with fluids that eventually are used towash textiles with hot water; coal-fired power plants—combustion air ispreheated in step (3 a); and gas-fired power plants—methane andcombustion air is preheated in step (3 a).

Another aspect of this invention is a heat exchange process having thesteps where: step (1 b) the heat exchanges between the source ofelectromagnetic energy and part of the input chemical species flowoccurs; step (1 c) another part of the input chemical species flow isfurther heated by heat exchange between the exiting hot, output-chemicalspecies flow by exchange of heat with either conventional pipe heatexchanger, heat pipes, charged air coolers or other means; step (1 d)all input chemical species flows are mixed prior to entering the devicefor treatment; step (2) then the entire input chemical species flowenters the device for treatment; and step (3) the output chemicalspecies exhausts through the heat exchange system. Step (3 a) disclosedin the preceding paragraph can be added to this heat exchange process ifneeded.

Another embodiment of this invention is a structure of the gas-permeablesusceptor 9. This invention embodies a macroscopic artificial dielectricstructure for the gas-permeable susceptor 9. The embodied gas-permeablemacroscopic artificial dielectric susceptor can be a honeycombstructure, foam, or woven fabric filter with a pattern, or a structureconsisting of discrete susceptors, which are referred to herein as unitsusceptors. This invention embodies the gas-permeable, macroscopicartificial dielectric susceptor to allow for applied electromagneticenergy 6 to penetrate the distance between the primarily reflectivecomponents, whether a discrete susceptor, a coating pattern or wovenpattern structure so the structure does not act as a collection ofwaveguides with cut-off frequencies that prevents the applied energy 6from penetrating the width of interaction 12. The gas-permeable,macroscopic artificial dielectric susceptor embodies a) an articleconstructed of a material where the article has a coating applied in aspecific pattern to create a macroscopic artificial dielectric structurefrom the coating and the article, b) a woven structure that contains twoor more different materials as threads (or yarns) which woven togetherto form a macroscopic artificial dielectric structure, or c) a structurethat consists of a mixture of discrete suscepting articles where themixture contains discrete articles that have different dielectricproperties and surround each other to form a macroscopic artificialdielectric structure.

When the embodied invention, the gas-permeable macroscopic artificialdielectric structure, has an article which is a honeycomb structureconstructed of a material, some of the cell walls of the honeycomb canbe coated with materials that have different dielectric properties toproduce a macroscopic artificial dielectric. The pattern of cells withcoated walls are arranged in the honeycomb so that the appliedelectromagnetic energy and energies penetrate the suscepting structureand either heat the susceptor or scatter the energy for interaction withthe gases/particulate in the air stream. The pattern of the cell wallsattenuate the applied electromagnetic energy by either a) partially orcompletely by absorbing the applied energy, producing fluorescentradiation to heat the remaining parts of the susceptor and the airstream or b) partially or completely scattering applied energy toconcentrate the applied energy for interaction with the air stream or toheat the remaining volume of the susceptor. Also, the embodiedmacroscopic artificial dielectric can be made from the honeycombstructure by filling some of the cells with another material.Additionally, the invention embodies 1) a large honeycombed-shaped,macroscopic artificial dielectric structure that is constructed fromsmaller discrete susceptor articles that are small honeycombed shapedarticles that have differing dielectric properties and/or conductivityor 2) smaller discrete susceptor articles that are honeycombed-shapedthat have the same dielectric property and are cemented together with amaterial which has different dielectric properties and/or conductivity.This invention also embodies the same or similar methods used to createhoneycombed-shaped macroscopic artificial dielectrics to be employed tocreate macroscopic artificial dielectrics out of foams and weaves.

When the embodied macroscopic artificial dielectric susceptor isdesigned as a structure that consists of unit susceptors, susceptors canbe designed for complex interaction with the applied energy or energiesas previously described in Example Three. Potentially, each unitsusceptor can have separate characteristics for absorption,transmission, scattering and reflection of 1) applied electromagneticenergy or energies, 2) subsequent fluorescent radiation produced fromthe applied electromagnetic energy or energies, and 3) the subsequentradiation from heat resulting from the dielectric loss within eachindividual susceptor. The separate characteristics of absorption,transmission, scattering and reflection of a unit susceptor embodied inthis invention are controlled by the unit susceptor's length, thickness,shape, composite materials structure, material selection, porosity, poresizes, temperature dependence of the complex dielectric constant andthermal conductivity.

FIG. 5 describes the structure of the macroscopic artificial dielectricsusceptor 15 by using a two-dimension array of squares that representunit susceptors. Although the optical properties of each unit susceptorwithin the embodied macroscopic artificial dielectric susceptorstructure 15 can be independent, the embodied structure of themacroscopic artificial dielectric susceptor 15 will dictate theinteraction of the macroscopic susceptor with the appliedelectromagnetic energy 6. The structure of the macroscopic artificialdielectric susceptor will be described with the unit susceptors that areprimarily reflective 16. This invention, the gas-permeable, macroscopicartificial dielectric susceptor 15, embodies the principle of reflectionto provide diffuse reflection, scattering, as means for allowing theapplied energy 6 to penetrate the width of interaction 12 in susceptor9, to volumetrically interact with susceptor 9, to produce the desiredmethod of treatment to react gases for desired products or to treatpollutants for producing clean air which can be discharged into theenvironment in accordance with the law of the land.

The reflectivity of the embodied macroscopic artificial dielectricsusceptor 15 is controlled by the volume and interconnectivity of theunit susceptors 16, which are the primarily reflective unit susceptorsin the macroscopic susceptor. The primarily reflective unit susceptors16 are defined as being the unit susceptors to which are primarilyreflective to the applied energy 6 or energies. The gas-permeable,macroscopic artificial dielectric susceptor has the primarily reflectiveunit susceptors 16 surrounded by unit susceptors 17 that are eitherprimarily transparent or partially absorptive of the applied energy orenergies. The primarily reflective unit susceptors 16 scatter theapplied energy 6 within susceptor 9, concentrating the applied energy tointeract with either a) the primarily transparent or partiallyabsorptive unit susceptors 17 or b) the reactant gases, pollutants orparticulates.

As the volume of the primarily reflective unit susceptors 16 increasesin the gas-permeable, macroscopic artificial dielectric susceptor 15, adegree of interconnectivity of the primarily reflective unit susceptors16 will occur, forming an interconnective network within thegas-permeable, macroscopic artificial dielectric susceptor 15, as shownin FIG. 6. The degree or amount of interconnectivity will depend on thesize and shape of the primarily reflective unit susceptors 16. Theability of the applied energy 6 or energies to penetrate the macroscopicartificial dielectric susceptor 15, 9 will depend not only on the volumeof the primarily reflective unit susceptor 16, but also on the degreeand amount of interconnectivity. When the degree of interconnectivity ofthe primarily reflective unit susceptors 16 throughout the entiregas-permeable macroscopic artificial dielectric susceptor 15, 9 is suchthat maximum distance between the interconnected network 18 of theprimarily reflective unit susceptors 16 does not allow for appliedenergy 6 to penetrate or the longest wavelength of the applied energies6 to penetrate, the gas-permeable macroscopic artificial dielectricsusceptor 9, 15 itself, will become primarily reflective to either a)the applied electromagnetic energy or b) the longest wavelength of theapplied energies, and volumetric interaction between the applied energy6 with susceptor 9 will not occur. The volume of susceptor 9 given bythe production width of interaction 12 by the length of the susceptor bythe breadth of the susceptor will not have 50% of the appliedelectromagnetic energy disturbed volumetrically within the volume.

This invention embodies a gas permeable susceptor with macroscopicartificial dielectric structure, which allows for the appliedelectromagnetic energy 6 to be able to penetrate the distance 18 betweenprimarily reflective unit susceptors 16, allowing for volumetricinteraction within susceptor 9. The embodiments of this invention can beapplied to honeycomb structures, weaves and foams when reflectivecoating are applied to the structure or the structure are constructed ofsmaller pieces that are primarily reflective suscepting units.

The invention embodies a high degree of interconnectivity of primarilyreflective unit susceptors 16. A high degree of interconnectivity can bebeneficial in some instances. This invention embodies the use ofclusters of primarily reflective unit susceptors 16 to be distributedabout the macroscopic artificial susceptor to promote scattering.Primarily reflective unit susceptors can be aggregated to form shapesand boundaries that reflect one or more wavelengths of the appliedenergy or energies.

This invention embodies a macroscopic artificial dielectric structurefor the gas-permeable susceptor 9 where the volume fraction andinterconnectivity of the reflective unit susceptors 16 surroundingpartially absorbing or primarily transparent unit susceptors 17 as ameans to design specific macroscopic artificial dielectric structures a)for resonant cavities that are based upon the wavelength of the appliedenergy in the susceptor, b) for scattering energy for interaction withgas or particulate species, c) that concentrate energy at fieldconcentrators which are located on other unit susceptors, d) thatconcentrate energy within the susceptor for increase reactivity betweenthe gas stream and the fluorescent radiation, e) that have the primarilyreflective unit susceptors arranged in such a manner to produce a largespiral, helical or other shape with the macroscopic susceptor, f) thatact as shielding to prevent the applied electromagnetic from enteringmaterial inside the cavity for thermal insulation, g) that preventleakage outside the cavity by the applied energy, h) that reflectapplied energy to other regions of the artificial dielectric to provideeither higher temperatures or increased energy for reaction ordestruction of gaseous/particulate species, and i) that regulate thetemperature of the gas-stream.

This invention also embodies a gas-permeable susceptor 9 with amacroscopic artificial dielectric structure, which uses reflection,scattering and concentration of the applied electromagnetic energy as ameans a) to react gases for desired products, b) to regulated thetemperature of the air stream, c) to prevent the device fromoverheating, d) to prevent deleterious reactions between the materialsof construction, e) to heat a gas stream or chemical species stream, f)to create a device of substantial size for adsorption and regenerationof gaseous species from a mixture of carbon-containing susceptor andzeolite-containing susceptors, and g) to produce a desired ratio of aself-limited temperature to power concentration of applied energy orenergies to perform the desired utility.

This invention embodies primarily of the unit susceptors 16 that areproduced from metallic or intermetallic materials species at roomtemperature or materials such as semiconductors, ferroelectrics,ferromagnetics, antiferroelectrics, and antiferromagnetics that becomereflective at elevated temperatures. The embodied unit susceptor'smaterials that produce reflection are either a) homogeneous materials,b) composite materials having a second phase material in a matrix thatis partially absorptive to applied electromagnetic energy where thevolume fraction of the second phase materials can be used to control theamount of reflection of a unit susceptor, or c) a coating on a unitsusceptor. This invention also embodies the length, width and shape ofthe primarily reflective unit susceptors 16 and the distance betweenreflective unit susceptors 18 to control the reflectivity of thegas-permeable, macroscopic artificial dielectric susceptor.

The shape of the unit susceptor can be designed for reflection. Theinvention embodies the shape of the unit susceptor that are eitherchiral, spire-like, helical, rod-like, acicular, spherical, ellipsoidal,disc-shaped, needle-like, plate-like, irregular-shaped or the shape ofspaghetti twist in Muller's Spaghetti and Creamette brand. Thisinvention embodies the shape of the unit susceptor to produce turbulencein the airflow, thus providing for mixing of reactants in the gaseous orliquid stream. The shape and size of the susceptor can be used to gradethe pore size of the susceptor to accommodate the expansion of gas dueto passing through the hot zone.

Another embodiment of this invention is unit susceptor 19 that isillustrated in FIG. 7. Unit susceptors 19 can make up the gas-permeable,macroscopic artificial dielectric susceptor 15. The unit susceptor's 19shape can be chiral, spire-like, helical, rod-like, acicular, spherical,ellipsoidal, disc-shaped, irregular-shape, plate-like, needle-like orthe shape of a Muller's spaghetti twist (rotini). The susceptor 19 canbe an artificial dielectric material, made from a homogeneous materialor have a coating on the unit susceptor that is either made from ahomogeneous material or artificial dielectric material. The length ofunit susceptor 19 should be greater than 0.25 inches and the widthshould be greater than 1/16th of an inch.

The absorption, transmission, reflection, scattering and the complexdielectric constant of unit susceptors 19 can be controlled by usingartificial dielectric materials. The structure of a unit susceptor 19made from an artificial dielectric material is shown FIG. 7. The unitsusceptor 19 has a matrix material 20 which contains a second phasematerial 21 or third phase material 12. The purpose of using anartificial dielectric material for a unit susceptor 19 is to produceprimarily reflective unit susceptors 16. The reflectivity of theprimarily unit susceptors 16 can be controlled by size, volume fractionand shape of the second phase material 21 or third phase material 12. Avolume fraction of the second phase material over 50% can produce aninterconnected network of the second phase materials, which has areflectivity that behaves the same as higher volume fractions. The shapeof the second phase can be chiral, spire-like, helical, rod-like,acicular, spherical, ellipsoidal, disc-shaped, irregular-shape,plate-like or needle-like. A size range of the second phase 21, which isfrom the group of materials known as semiconductors, conductors,ferromagnetics, ferroelectrics, ferrimagnetics and antiferroelectrics isembodied in this invention.

The size-range which is embodied in this invention for the second phaseis a particle size range that is −325 U.S. Mesh Sieve Size or less(equivalent to sizes less than 46 microns). The embodied small particlesize range is used because these particle sizes will rapidly absorbelectromagnetic energy, elevating the temperature of the particles' veryhigh temperature where the particles' material will become veryconductive and/or exceed the Curie temperature, rendering the unitsusceptor to be reflective. Another embodiment of this invention is thatthe thermal expansion mismatch between the second phase material 21 andthe matrix 20 be less than 15%, in order to prevent the unit susceptor19 from becoming friable. Another embodiment of this invention is amethod to reduce the thermal expansion mismatch by the unit susceptor'ssecond phase material 21 being the same crystalline structure and basematerial as the matrix material 20, however the second phase's material21 is doped on the lattice structure with a cation or anion to increasethe electrical conductivity of the second phase's material whileproducing a very low thermal expansion mismatch between the matrix 20and the second phase material 21. Another embodiment of this inventionis to have the particle size of the second phase material 21 be in thesize range of between 200 microns and 3 mm in the unit susceptor 19 whenstrong potential for deleterious chemical reaction between the matrix 20and the second phase material 21 in unit susceptor 19.

Additionally, the composite materials for unit susceptors can use acombination of materials in such a fashion where the selected materialsproduce thermoluminescent, incandescent and phosphorescent radiation.

Another embodiment of this invention is the use of field concentrators22 on unit susceptors 19 as illustrated in FIG. 8. This inventionembodies the use of field concentrators 22 to concentrate theelectromagnetic field locally so a high intensity electromagnetic fieldis available to interact with gaseous/particulate species to eitherdrive chemical reaction, enhance the reaction between chemical species.This invention embodies materials of construction of field concentrators22 that are a) conductors, b) semi-conductors, c) materials with a CuriePoint, d) ionic-conducting ceramic, e) composite materials from a and c,f) composite materials from b and c, g) composite materials from a andd, and h) composite materials from b and d. This invention embodies theshape of field concentrators 22 to be selected from shapes that arechiral, spire-like, helical, rod-like, acicular, spherical, ellipsoidal,disc-shaped, irregular-shape, plate-like, needle-like or have a shapethat has sharp-pointed-gear-like teeth.

This invention embodies a size range for the field concentrators 22 thatis used to prevent deleterious chemical reaction between the fieldconcentrators 22 and unit susceptor 19. The size of the fieldconcentrators can be one to 10 times the depth of penetration of appliedelectromagnetic energy of materials of construction, either at roomtemperature or the operating temperature. This size difference dependson the chemical compatibility between the field concentrators and theunit susceptor's materials of construction. Where there is littleconcern for deleterious reaction between the unit susceptor and fieldconcentrator, then the size of the field concentrator, which, based onits depth of penetration of the materials of construction, can be 1 to10 times the depth penetration at the operating temperature. If there isgreat concern for deleterious reaction between the unit susceptor andfield concentrator, then the size of the field concentrator should besuch not to promote reaction, 200 microns to 4 mm.

Additionally, this invention embodies the use of a barrier coating 23between the field concentrators 22 and the unit susceptor 19 to preventdeleterious chemical reaction between the field concentrator and theunit susceptor. Also, this invention embodies materials of constructionfor field concentrators 22 including 1) a thermoluminescent material, 2)a phosphorescent material, 3) an incandescent material, 4)ferroelectric, 5) ferromagnetic, 6) ferrimagnetic, 7) MnO₂, 8) TiO₂, 9)CuO, 10) NiO, 11) Fe₂O₃, 12) Cr₂O₃, 13) Li₂O doped MnO₂, 14) Li₂O dopedCuO, 15) Li₂O doped NiO, 16) CuO—MnO₂—Li₂O complex, 17) CuO—MnO₂, 18)silicide, 19) borides, 20) aluminides, 21) nitrides, 22) carbides, 23)ceramic glazes with metal particles, 24) ceramic glazes withsemi-conducting particles, 25) materials that produce thermionicemissions, and 26) thermoelectric materials.

This invention embodies the production of ozone from field concentrators22 on unit susceptor 19 as shown in FIG. 8. When the distance (gap) 23between two field concentrators 22, which are made from materials whichare conducting or semi-conducting are at such a distance, the appliedelectromagnetic field 6 can cause a discharge of a spark from localizedfields that are produced by the applied electromagnetic energy,producing ozone. The invention also embodies the production of ozone onthe surfaces of unit susceptors 19 which are constructed of artificialdielectric material as shown in FIG. 7. A spark can occur from a gap 24between the exposed surfaces of the second phase material 21 and ozonecan be produced. This invention embodies the production of ozone thatcan occur at elevated temperatures and when the volume fraction of thesecond phase material 21 exceeds twenty percent (20%). Also, thisinvention embodies the production of ozone from electric discharges thatcan occur a) between two unit susceptors 19 in close proximity thatcontain field concentrators 22, b) between exposed surfaces of secondphase material 21 from two unit susceptors in close proximity, and c)between two unit susceptors 19 where one unit susceptor 19 contains afield concentrator 22 and the one unit susceptor contains an exposedsurface of a second phase material 21.

The above description sets forth the best mode of the invention as knownto the inventor at this time, and is for illustrative purposes only, asone skilled in the art will be able to make modifications to thisprocess without departing from the spirit and scope of the invention andits equivalents as set forth in the appended claims.

Field Concentrators

This invention embodies different locations for field concentrators in asusceptor. The susceptor can be a macroscopic susceptor 15 or a unitsusceptor 19. As shown in FIG. 9, a field concentrator can be located onthe surface of a susceptor 22, embedded in a surface of susceptor 22 a,or embedded in the matrix 22 b, of a susceptor. A susceptor can have acombination of these locations of field concentrators to generate localelectric fields. When a field concentrator 22 b is embedded in thesusceptor, the matrix 20 would be made of a material that has enoughpermittivity and permeability to the applied electromagnetic energy andenough permittivity and permeability that allows for producing a localfield about the surface of the susceptor from embedded fieldconcentrator 22 b. A susceptor can contain a plurality of fieldconcentrators. As shown in FIG. 7, the non-matrix material 21 that isembedded in the surface of susceptor 19 can behave as fieldconcentrators as mentioned earlier to produce ozone. Additionally, whenthe field concentrator is on the surface 22 or embedded in the surfaceof a susceptor 22 a the susceptor can be a homogeneous material, not acomposite. The homogeneous material of the susceptor can either bereflective to the applied electromagnetic energy, be an insulator, be amaterial that has a Curie temperature, a material that has dielectriclosses or a material that absorb at least a portion of the appliedelectromagnetic energy.

Another aspect of this embodiment is that reflective non-matrix material21 b can be used to reflect applied electromagnetic energy to a fieldconcentrator to increase the local electric field. As shown in FIG. 9,the reflective non-matrix material 21 b is a material that is primarilyreflective to the applied electromagnetic energy at room temperature ora material that becomes reflective to the applied electromagnetic energyat temperatures greater than room temperature.

The invention also is a method of locally concentrating an appliedelectric field to promote chemical reaction having a dispersion ofindividual field concentrators at a location selected from the groupconsisting of on the surface of a substrate, embedded on a substrate,and embedded on the surface of a substrate, wherein the individual fieldconcentrators consists of shaped material and the shape and material arecapable of producing a locally concentrated electric field in thevicinity of the field concentrator from interaction between the fieldconcentrator and the applied electric field.

The shape of an individual field concentrator can be selected from thegroup consisting of chiral shape, spire-like shape, shape cylindricalshape, tubular shape, helical shape, rod-like shape, plate-like shape,acicular shape, spherical shape, ellipsoidal shape, disc-shaped shape,irregular-shaped shape, plate-like shape, needle-like shape, twistshape, and a shape like a pasta rotini twist.

The size of an individual field concentrator preferably is between onenanometer and one meter.

The material for an individual field concentrator preferably is selectedfrom the group of materials consisting of a material that is capable ofcreating an electric field, a chalcogenide, a metal alloy, asolid-solution crystalline material, a Fe-based alloy, a precious metalalloy, an artificial dielectric, an artificial dielectric material wherethe volume fraction of the non-matrix species is less that 50 volumepercent, an artificial dielectric material where the volume fraction ofthe non-matrix species is equal to or greater than 50 volume percent, amaterial that produces thermionic emissions, a material that isthermoelectric, a cermet, a composite material, an organic polymericmatrix composite, a ceramic matrix composite, a metal matrix composite,copolymer, a Co-alloy, a Ni-alloy, antiferromagnetic, antiferroelectric,paramagnetic, a material with a Curie temperature, glassy, metallic,ferrimagnetic, ferroelectric, ferromagnetic, semiconducting, conducting,a solid-state ionic conductor, a non-stoichiometric carbide, anon-stoichiometric oxide, an oxycarbide, an oxynitride, a carbonitride,an intermetallic, a hydroxide, thermoluminescent, fluorescent, a boride,a material with low dielectric constant and low dielectric losses, amaterial with a high dielectric constant and low dielectric losses, Fe,Co, Ni, a silicide, a nitride, an aluminide, a material with a highdielectric constant and high dielectric losses, a material with a highdielectric constant and moderate dielectric losses, a carbide, an oxide,anatase, a sulfide, a sulfate, carbonate, FeO, CuO Cu₂O, MnO₂ Mn₂O₅,NiO, Fe₂O₃, Fe₃O₄, Li₂O—NiO, TiO₂ doped with a divalent cation, TiO₂doped with a trivalent cation, Fe₂O₃ doped with Ti⁺⁴, CuO—MnO₂,Cu₂O—MnO₂, Li₂O—Cu₂O, Li₂O—CuO, Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y),TiC_(1-x), TiO₂, a non-stoichiometric titanium oxide, TiO, Ti₂O₃, anon-stoichiometric zirconia oxide, anatase, beta″-alumina,alpha-alumina, Na-beta-alumina, Li-beta-alumina, (Na,Li)-beta-alumina, acarbon, a graphite, ZnO, CuS, FeS, CoO, a calcium aluminate, char, Ni,Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃,MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x), FeTiO_(3-x), ap-type material, an n-type material, a cation-doped p-type dominatematerial, an anion-doped p-type dominate materials, a cation-dopedn-type dominate material, an anion-doped n-type material, a metal, anamorphous material, and a non-stoichiometric nitride.

A coating also can be placed between the substrate and fieldconcentrator wherein the utility of coating is selected from the groupof utility consisting of a coating containing a catalyst for catalysis,a coating to prevent deleterious reaction between the field concentratorand the susceptor's materials of construction, a coating that is used toadhere the field concentrator to the susceptor, a coating to provideelectrical insulation between the field concentrator and the susceptor'smaterials of construction, a coating to create a strong local electricfield where the coating's material has a high dielectric constant withlow dielectric losses, a coating to create a strong local electric fieldwhere the coating's material has a moderate dielectric constant anddielectric losses, a coating that is a semiconductor where the coatingheats due to the field concentration of the field concentrator, andcombinations thereof.

The substrate preferably is constructed of low-loss dielectric materialselected from the group of materials consisting of alumina,aluminosilicate ceramic, magnesium aluminosilicate ceramic, magnesiumsilicate, calcium silicate, calcium aluminosilicate, clay, zeolite,magnesium oxide, sialon, oxynitride, inorganic glass, organic glass,organic polymer, crystalline organic polymer, a polymer composite,cordierite, enstatite, forsterite, steatite, nitride, porcelain,high-temperature porcelain, a glass ceramic, a phase separated glass, alithium-aluminosilicate, Teflon, a organic copolymer, polycarbonate,polypropylene, polystyrene, polyethylene, polyester,polytetrafluoroethylene, and combination thereof.

The substrate also can be constructed of materials selected from thegroup of materials consisting of a material that is amorphous,polycrystalline, antiferromagnetic, antiferroelectric, paramagnetic, anartificial dielectric, an artificial dielectric material where thevolume fraction of the non-matrix species is less that 50 volumepercent, an artificial dielectric material where the volume fraction ofthe non-matrix species is equal to or greater than 50 volume percent, amaterial that produces thermionic emissions, a material that isthermoelectric, a cermet, a composite, a material with a Curietemperature, glassy, metallic, ferrimagnetic, ferroelectric,thermochromatic, photochromatic, ferromagnetic, semiconducting,conducting, a solid-state ionic conductor, a non-stoichiometric carbide,a non-stoichiometric oxide, an oxycarbide, an oxynitride, acarbonitride, an intermetallic, a hydroxide, a non-stoichiometricnitride, thermoluminescent, a non-stoichiometric Ilmenitic structure,fluorescent, a boride, a material with low dielectric constant and lowdielectric losses, a material with a high dielectric constant and lowdielectric losses, an oxide, a silicide, a nitride, an aluminide, amaterial with a high dielectric constant and high dielectric losses, amaterial with a high dielectric constant and moderate dielectric losses,a carbide, an oxide, anatase, a sulfide, a sulfate, a carbonate, a glassceramic, a phase separated glass, an ionic conductor, a catalyst, amaterial derived by processing a clay mineral with heat to a temperatureand for time period above the temperature that the water ofcrystallization is removed and below a temperature and for time periodthat prevent complete transformation of the clay material tonon-reversible crystalline and/or glass phases, a material derived byprocessing talc with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe talc material to non-reversible crystalline and/or glass, a materialderived by processing a zeolite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the zeolite material to non-reversiblecrystalline and/or glass phases, a material derived by processingBrucite with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe Brucite material to non-reversible crystalline material, a materialderived by processing a Gibbsite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the clay material to non-reversiblecrystalline material, and combinations thereof.

The preferred clay mineral is selected from the group consisting of amontmorillonite, a ball clay, illite, dickite, halloysite, a mica, azeolite, a koalinite, an illitic clay, pyropholite, Endellite,bentonite, chlorite, and combinations thereof.

The distance between any two field concentrators prevents the formationof a spark.

The field concentration can be used for the function selected from thegroup of functions consisting of to drive chemical reactions, to assistin chemical reactions, to drive polymerization, to assist inpolymerization, to assist in catalysis, oglomerization, or combinationthereof, wherein the reaction occurs in physical phases of matter fromthe group consisting of a plasma, gas, solid, liquid, a fluid containingparticulates, and combinations thereof.

The size of an individual field concentrator preferably is less than 20times the depth of penetration of at least one wavelength of appliedelectromagnetic energy in the material that the individual fieldconcentrator is constructed of.

The field concentration preferably has utility that is selected from thegroup of utility that reforms a hydrocarbon, causes polymerization,reduces nitrogen oxides to nitrogen (N₂), reduces NO to nitrogen (N₂),reduces NO₂ to NO, reduces NO₂ to nitrogen (N₂), reduces SO_(x) tosulfur (S), reduces SO₃ to SO₂, reduces SO₄ to SO₂, reduces SO₃ to SO₂,produces chemical synthesis, allows for sterilization, produces crackingof a hydrocarbon, decreases the activation energy of a chemical process,oxidizes volatile organic compound to carbon dioxide and water, oxidizescarbon monoxide to carbon dioxide, synthesizes pharmaceuticals, reducesNO_(x) in the presence of hydrocarbons, synthesizes biodiesel, reforms ahydrocarbon with a hydrogen donor species in the presence of H₂O,reforms a hydrocarbon with methane in the presence of H₂O, reforms ahydrocarbon in the presence of methane, water and carbon dioxide,reforms a hydrocarbon in the presence of methane, water, hydrogen andcarbon dioxide, reforms a hydrocarbon in the presence of hydrogen andmethane, polymerizes a hydrocarbon in the presence of metal halides,reduces nitrogen oxides in the presence of ammonia, reduces nitrogenoxides in the presence of ammonium-containing compounds, treatspollutants to form clean air which can be discharged into theenvironment in accordance to the law of the land, produces oxidativebond cleavage of a hydrocarbon and produces non-oxidative bond cleavageof a hydrocarbon, wherein the reaction occurs in physical phases ofmatter from the group consisting of a plasma, gas, solid, liquid, afluid containing particulates, and combinations thereof.

The method of field concentration is used in an atmosphere preferablyselected from the group of atmosphere consisting of a reducingatmosphere, an oxidizing atmosphere, an atmosphere at one atmosphere ofpressure, an atmosphere at less than one atmosphere of pressure, anatmosphere at greater than one atmosphere of pressure, and combinationsthereof.

The field concentrator's electronic properties preferably are selectedfrom the group consisting of a p-type material, an n-type material, acation-doped p-type dominate material, an anion-doped p-type dominatematerials, a cation-doped n-type dominate material, an anion-dopedn-type dominate material, and combinations thereof.

The method electromagnetic properties of the field concentrator'smaterials preferably is control by a crystalline defect. The defectpreferably is selected from the group of consisting of an intrinsicdefect, an extrinsic defect, defect from cation substitution, a defectfrom anion substitution, and combinations thereof.

The operating temperature of the method of field concentrationpreferably is selected from the group of operating conditions consistingof a temperature which is above the Curie temperature of all the fieldconcentrators' materials, a temperature which is below the Curietemperature of all the field concentrators' materials, a temperaturewhich is above Curie temperature of the non-matrix material only, atemperature which is above the Curie temperature of the matrix materialonly, a temperature which is above the Curie temperature of all thesusceptor's materials causing increased absorption, a temperature whichis above the Curie temperature of the non-matrix causing increasedabsorption, a temperature which is above the Curie temperature of thematrix causing increased absorption, a temperature above the thermalrunaway temperature (critical temperature) of at least one of theconstituent phases, a temperature which is below the thermal runawaytemperature (critical temperature) of all the constituent phases, atemperature which is below the activation temperature of the intrinsicdielectric conduction species of all the phases present, a temperaturewhich is above the activation temperature of at least one intrinsicdielectric conducting species of all constituent phases, a temperaturewhich is below the activation temperature of all extrinsic dielectricconducting species, a temperature which is above the activationtemperature of at least one extrinsic dielectric conducting species ofall the constituent phases, and combinations thereof.

The field concentrator preferably is of a size that is designed tolessen any deleterious chemical reaction between the materials ofconstruction of the electromagnetic susceptor and the materials ofconstruction of the field concentrator.

The field concentrator also may further comprise a catalyst.

The applied electromagnetic energy is applied in the form of continuousenergy, pulsed energy or combination thereof.

The method substrate also can be permeable to a chemical species flow.

An illustrative chemical reaction is the production of ozone frominteraction between a field concentrator and applied electromagneticenergy by having two or more field concentrators on a substrateconstructed of a low-loss dielectric material having a distance betweeneach field concentrator such that a spark is capable of being producedapplying electromagnetic energy to the substrate that contains saidfield concentrators causing a spark discharge while passing a chemicalspecies flow containing oxygen over said substrate.

A second illustrative chemical reaction is the production of ozone frominteraction between a non-matrix material and applied electromagneticenergy by exposing a composite substrate to electromagnetic energy inwhich a portion of the non-matrix material is embedded in the surface ofa susceptor and is exposed above the surface of a susceptor having amatrix constructed of a low-loss and low dielectric constant material,and applying electromagnetic energy to the substrate causing a sparkdischarge while passing a chemical species flow containing oxygen ofsaid substrate.

The volume fraction of the non-matrix material is greater than 0% andpreferably greater than 20%.

Coatings

The invention also is a coated susceptor of electromagnetic energy forchemical processing comprising:

a matrix material that surrounds a non-matrix material that is made froma material that is different from the matrix material, wherein thematrix material is constructed of material having lower dielectriclosses compared to the non-matrix material, wherein:

a. the non-matrix material initially absorbs electromagnetic energyapplied to the electromagnetic susceptor to a greater extent than thematrix material;

b. the non-matrix material produces subsequent heat in the matrixmaterial; and

c. the surface of the susceptor is coated with a material that interactswith applied electromagnetic energy of at least one frequency andinitially absorbs electromagnetic energy and produces heat.

The non-matrix material also can produce reflection.

The form of said coating preferably is selected from the groupconsisting of a full coating on all susceptor surfaces, a full coatingon a surface, a partial coating on a surface, a partial coating on allsusceptor surfaces, a coating with a specific pattern, a coatingcontaining a homogeneous material, a coating containing a compositematerial, a partial coating containing a more than one material, apatterned coating containing more than one material, a coatingcontaining multiple layers of different material, and combinationsthereof.

The weight fraction of said non-matrix material preferably is greaterthan 0.00001 weight percent and less than 50 weight percent. The weightfraction of said non-matrix material preferably is greater than 50weight percent and less 99.9 weight percent.

The coating preferably has optical dielectric properties in relation tothe applied electromagnetic energy selected from the group consisting oftransparent, reflective, scattering, absorptive, and combinationsthereof.

The coating can provide a utility to effect a physical property of saidsusceptor selected from the group consisting of mechanical properties,thermal properties, optical properties of the non-matrix material,optical properties of the susceptor, absorption of electromagneticenergy, reflection of electromagnetic energy, transmission ofelectromagnetic energy, scattering of electromagnetic energy,electromagnetic properties, corrosive properties, wear properties,piezoelectric properties, dielectric properties, magnetic properties,electric properties, susceptibility to the applied electromagneticenergy, susceptibility to the fluorescent electromagnetic energy,conductivity, controlling the chemical compatibility between thenon-matrix material and the matrix material, regulating the temperatureof said susceptor, regulating the temperature of a process, regulatingthe amount of electromagnetic energy available for chemical process,regulating the amount of electromagnetic energy available for a physicalprocess, and combinations thereof.

The physical properties often are controlled by the thickness of thecoating.

The coated susceptor can be used in an atmosphere selected from thegroup consisting of a reducing atmosphere, an oxidizing atmosphere, anatmosphere at one atmosphere of pressure, an atmosphere at less than oneatmosphere of pressure, an atmosphere at greater than one atmosphere ofpressure, and combinations thereof.

The coating can be constructed of a material selected from the groupconsisting of metallic, amorphous, polycrystalline, antiferromagnetic,antiferroelectric, paramagnetic, a material with a Curie temperature,glassy, metallic, ferrimagnetic, ferroelectric, ferromagnetic,semiconducting, conducting, a solid-state ionic conductor, anon-stoichiometric carbide, a non-stoichiometric oxide, an oxycarbide, amaterial that produces thermionic emissions, a material that isthermoelectric, a cermet, a ceramic glaze with metal particles, anoxynitride, a carbonitride, an intermetallic, a hydroxide, anon-stoichiometric nitride, thermoluminescent, a composite material, anorganic polymeric matrix composite, a ceramic matrix composite, a metalmatrix composite, a crystalline form of silica, fused silica, quartz, aorganic copolymer, an amorphous organic polymer, a crystalline organicpolymer, polycarbonate, polypropylene, polystyrene, polyethylene,polyester, polytetrafluoroethylene, a non-stoichiometric llmeniticstructure, fluorescent, an artificial dielectric material, an artificialdielectric material where the volume fraction of the non-matrix speciesis less that 50 volume percent, an artificial dielectric material wherethe volume fraction of the non-matrix species is equal to or greaterthan 50 volume percent, a boride, a material with low dielectricconstant and low dielectric losses, a material with a high dielectricconstant and low dielectric losses, a silicide, a nitride, an aluminide,a material with a high dielectric constant and high dielectric losses, amaterial with a high dielectric constant and moderate dielectric losses,a carbide, an oxide, anatase, a sulfide, a sulfate, a crystalline formof silica, a carbonate, a glass ceramic, photochromatic,thermochromatic, a phase separated glass, an ionic conductor, a materialderived by processing a clay mineral with heat to a temperature and fortime period above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the clay material to non-reversiblecrystalline and/or glass phases, a material derived by processing talcwith heat to a temperature and for time period above the temperaturethat the water of crystallization is removed and below a temperature andfor time period that prevent complete transformation of the talcmaterial to non-reversible crystalline and/or glass, a material derivedby processing a zeolite with heat to a temperature and for time periodabove the temperature that the water of crystallization is removed andbelow a temperature and for time period that prevent completetransformation of the zeolite material to non-reversible crystallineand/or glass phases, a material derived by processing Brucite with heatto a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the Brucite material tonon-reversible crystalline material, and a material derived byprocessing a Gibbsite with heat to a temperature and for time periodabove the temperature that the water of crystallization is removed andbelow a temperature and for time period that prevent completetransformation of the clay material to non-reversible crystallinematerial or combination thereof.

The clay mineral preferably selected from the group consisting of amontmorillonite, a ball clay, illite, dickite, halloysite, a mica, azeolite, a koalinite, an illitic clay, pyropholite, Endellite,bentonite, chlorite and combinations thereof.

The coating can be constructed of a material selected from the groupconsisting of FeO, CuO Cu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃, Fe₃O₄, CuO—MnO₂,Cu₂O—MnO₂, Li₂O—Cu₂O, Li₂O—CuO, Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y),TiC_(1-x), TiO₂, non-stoichiometric titanium oxide, Li₂O—NiO, TiO₂ dopedwith a divalent cation, TiO₂ doped with a trivalent cation, Fe₂O₃ dopedwith Ti⁺⁴, TiO, Ti₂O₃, non-stoichiometric zirconia oxide, anatase,beta″-alumina, alpha-alumina, Na-beta-alumina, Li-beta-alumina,(Na,Li)-beta-alumina, carbon, graphite, ZnO, CuS, FeS, CoO, calciumaluminate, char, Ni, Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO₃,FeTiO₃, LiNbO₃, MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x),FeTiO_(3-x), and combinations thereof.

The coating can be an amorphous material that is at a temperature belowthe material's glass transition temperature during the chemicalprocessing.

The frequency of said applied electromagnetic energy can be selectedfrom the group consisting of visible, ultraviolet, radio frequency,microwave, infrared, a variable frequency source, 915 MHz, 2.59 GHz, andcombinations thereof.

The structure of said susceptor can be selected from the groupconsisting of chiral-shaped, spire-like shaped, helical shaped, rod-likeshaped, plate-like shaped, acicular shaped, spherical shaped,ellipsoidal shaped, disc-shaped, irregular-shaped, plate-like shaped, ashape of a spiral antenna species for at least one wavelength of appliedelectromagnetic energy, a shape of an antenna specified for at least onwavelength of applied electromagnetic energy, needle-like shaped, twistshaped, rotini shaped, a woven structure and honeycomb-like structure,multi-cell structure, cylindrical shaped, tubular shaped, a reticulatedstructure, a foamed structure, a capillary structure, and combinationsthereof.

The coated susceptor preferably is permeable to a chemical species flow.

The coated susceptor can be used as a plurality of susceptors forchemical processing in the form of an operation selected from the groupconsisting of fluidized bed, a slurry, a fluid mixture of susceptors andchemicals species flow, a gaseous mixture of particulate susceptors anda chemical species flow, a packed bed, a solid mixture of particulatesusceptors and a solid chemical species flow, and combination thereof.

The coating preferably becomes reflective at the operating temperatureof the chemical processing.

The coated susceptor can further comprising a field concentrator whereinthe location of the field concentrator is selected group from the groupconsisting of on the coating, embedded in the coating, in the coating,and combinations thereof.

The coating can have a function is selected from the group consisting ofdriving chemical reactions, assisting in chemical reactions,polymerization, producing biodiesel through catalysis, synthesizingpharmaceuticals, reducing nitrogen oxides to nitrogen (N₂), reducing NOto nitrogen (N₂), reducing NO₂ to NO, reducing NO₂ to nitrogen (N₂),reducing SO_(x) to sulfur (S), reducing SO₃ to SO₂, reducing SO₄ to SO₂,reducing SO₃ to SO₂, chemical synthesis, sterilization, crackinghydrocarbons, decreasing the activation energy of a chemical process,oxidizing volatile organic compounds, oxidizing carbon monoxide tocarbon dioxide, reducing NOx in the presence of hydrocarbons,synthesizing biodiesel, reforming a hydrocarbon with a hydrogen donorspecies in the presence of H₂₃, reforming a hydrocarbon with methane inthe presence of H₂₃, reforming a hydrocarbon in the presence of methane,water and carbon dioxide, reforming a hydrocarbon in the presence ofmethane, water, hydrogen and carbon dioxide, reforming a hydrocarbon inthe presence of hydrogen and methane, polymerizing a hydrocarbon in thepresence of metal halides, reducing nitrogen oxides in the presence ofammonia, reducing nitrogen oxides in the presence of ammonium-containingcompounds, treating pollutants to form clean air which can be dischargedinto the environment in accordance to the law of the land, oxidativebond cleavage of a hydrocarbon, non-oxidative bond cleavage of ahydrocarbon, catalysis, field concentration or combination thereof,wherein the reaction occurs in physical phases of matter from the groupconsisting of a plasma, gas, solid, liquid, a fluid containingparticulates, and combinations thereof.

The operating temperature of said susceptor can be selected from thegroup of operating conditions consisting of a temperature which is abovethe Curie temperature of all the susceptor's materials, a temperaturewhich is below the Curie temperature of all the susceptor's materials, atemperature which is above Curie temperature of the non-matrix materialonly, a temperature which is above the Curie temperature of the matrixmaterial only, a temperature which is above the Curie temperature of allthe susceptor's materials causing increased absorption, a temperaturewhich is above the Curie temperature of the non-matrix causing increasedabsorption, a temperature which is above the Curie temperature of thematrix causing increased absorption, a temperature above the thermalrunaway temperature (critical temperature) of at least one of theconstituent phases, a temperature which is below the thermal runawaytemperature (critical temperature) of all the constituent phases, atemperature which is below the activation temperature of the intrinsicdielectric conduction species of all the phases present, a temperaturewhich is above the activation temperature of at least one intrinsicdielectric conducting species of all constituent phases, a temperatureabove the Curie temperature of the coating's material, a temperaturewhich is below the activation temperature of all extrinsic dielectricconducting species, a temperature which is above the activationtemperature of at least one extrinsic dielectric conducting species ofall the constituent phases, and combinations thereof.

The coating can be selected from the group consisting of controlling theamount of absorption of the applied electromagnetic energy by saidsusceptor material, regulating the temperature of the susceptor,controlling the amount of reflectivity of the applied electromagneticenergy by said susceptor, and combinations thereof.

The applied electromagnetic energy often applied in the form ofcontinuous energy, pulsed energy or a combination thereof.

The coating can contain a material with catalytic properties. Thematerial with catalytic properties can have a molecular structureselected from the group consisting of amorphous, rock salt, zinc blend,antifluorite, rutile, perovskite, spinel, inverse spinel, nickelarsenide, corundum, ilimenite, olivine, cesium chloride, fluorite,silica types, wurtzite, derivative structure of a known crystallinestructure, a superstructure of a known crystalline structure,orthosilicate, metasilicate, gibbsite, graphite, zeolite, carbide,nitride, montmorillonite, pyrophyllite, intermetallic semiconductor,metallic semiconductor, garnet, psuedoperovskite, orthoferrite,hexagonal ferrite, rare earth garnet, and a ferrite.

The material with catalytic properties also can have electronicproperties selected from the group consisting of a p-type material, ann-type material, a cation-doped p-type dominate material, an anion-dopedp-type dominate materials, a cation-doped n-type dominate material, ananion-doped n-type material, and combinations thereof.

The coated susceptor also can have a barrier coating placed between saidcoating material with catalytic properties and said susceptor to preventdeleterious chemical reaction between said coating material withcatalytic properties and the susceptor, to help prevent the poisoning ofthe catalyst, or to help prevent a combination thereof.

The form of the catalytic material can be selected from the groupconsisting of a catalyst that is a full coating on all susceptorsurfaces, a catalyst that is partial coating on all susceptor surfaces,a catalyst that is particulate catalyst on the susceptor's surface, acatalyst that is particulate catalyst contained in a coating that is onthe susceptor, a catalyst that is particulate catalyst on a coating thatis on the susceptor, a catalyst that is full coating of all susceptorsurfaces that has an additional coating between the catalyst and thesusceptor, a catalyst that is a partial coating of all susceptorsurfaces that has an additional coating between the catalyst and thesusceptor, and combinations thereof.

The material with catalytic properties can be a composite selected fromthe group of catalytic composites consisting of two or more catalyststhat perform the same function, two or more catalysts where at least onecatalyst performs a different function than the other catalyst, two ormore catalysts where at least one catalyst is a metallic species, two ormore catalyst where at least one catalyst has a Curie temperature, andcombinations thereof.

The material with catalytic properties can have a function selected fromthe group consisting of driving chemical reactions, assisting inchemical reactions, polymerization, producing biodiesel throughcatalysis, synthesizing pharmaceuticals, reducing nitrogen oxides tonitrogen (N₂), reducing NO to nitrogen (N₂), reducing NO₂ to NO,reducing NO₂ to nitrogen (N₂), reducing SO_(x) to sulfur (S), reducingSO₃ to SO₂, reducing SO₄ to SO₂, reducing SO₃ to SO₂, chemicalsynthesis, sterilization, cracking hydrocarbons, decreasing theactivation energy of a chemical process, oxidizing volatile organiccompounds, oxidizing carbon monoxide to carbon dioxide, reducing NOx inthe presence of hydrocarbons, synthesizing biodiesel, reforming ahydrocarbon with a hydrogen donor species in the presence of H₂₃,reforming a hydrocarbon with methane in the presence of H₂₃, reforming ahydrocarbon in the presence of methane, water and carbon dioxide,reforming a hydrocarbon in the presence of methane, water, hydrogen andcarbon dioxide, reforming a hydrocarbon in the presence of hydrogen andmethane, polymerizing a hydrocarbon in the presence of metal halides,reducing nitrogen oxides in the presence of ammonia, reducing nitrogenoxides in the presence of ammonium-containing compounds, treatingpollutants to form clean air which can be discharged into theenvironment in accordance to the law of the land, oxidative bondcleavage of a hydrocarbon, non-oxidative bond cleavage of a hydrocarbon,catalysis, field concentration or combination thereof, wherein thereaction occurs in physical phases of matter from the group consistingof a plasma, gas, solid, liquid, a fluid containing particulates, andcombinations thereof.

The material with catalytic properties also can be selected from thegroup of materials consisting of a photocatalytic material activated byelectromagnetic energy in the ultraviolet region, a photo catalyticmaterial activated by electromagnetic energy in the visible region, ainfrared catalytic materials activated by electromagnetic energy in theinfrared region, a catalytic materials activated by electromagneticenergy in the microwave region, a catalytic material activated byelectromagnetic energy in the radio frequency region, and combinationsthereof.

The material with catalytic properties also can be selected from thegroup of consisting of materials that are a precious metal, Fe, Co, Ni,Pt, Pd, Au, Ag, chalcogenide, metal alloy, boride, Fe-based alloy, aprecious metal alloy, an artificial dielectric, an artificial dielectricmaterial where the volume fraction of the non-matrix species is lessthat 50 volume percent, an artificial dielectric material where thevolume fraction of the non-matrix species is equal to or greater than 50volume percent, Co-alloy, Ni-alloy, antiferromagnetic,antiferroelectric, paramagnetic, a material with a Curie temperature,glassy, metallic, a material that produces thermionic emissions, amaterial that is thermoelectric, a cermet, a ceramic glaze with metalparticles, ferrimagnetic, ferroelectric, ferromagnetic, semiconducting,conducting, solid-state ionic conductor, non-stoichiometric carbide,non-stoichiometric oxide, oxycarbide, oxynitride, carbonitride, oxide,nitride, intermetallic, hydroxide, thermoluminescent, fluorescent,boride, a material with low dielectric constant and low dielectriclosses, a material with a high dielectric constant and low dielectriclosses, silicide, nitride, aluminide, a material with a high dielectricconstant and high dielectric losses, a material with a high dielectricconstant and moderate dielectric losses, carbide, oxide, anatase,sulfide, sulfate, carbonate, FeO, CuO Cu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃,Fe₃O₄, CuO—MnO₂, Li2O—NiO, TiO₂ doped with a divalent cation, TiO₂ dopedwith a trivalent cation, Fe₂O₃ doped with Ti⁺⁴, Cu₂O—MnO₂, Li₂O—Cu₂O,Li₂O—CuO, Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂,non-stoichiometric titanium oxide, TiO, Ti₂O₃, non-stoichiometriczirconia oxide, anatase, beta″-alumina, alpha-alumina, Na-beta-alumina,Li-beta-alumina, (Na,Li)-beta-alumina, carbon, graphite, ZnO, CuS, FeS,CoO, calcium aluminate, char, Ni, Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃,NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃, MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x),CoTiO_(3-x), FeTiO_(3-x), ZnO_(1-x), SmLiO₂, LaLiO₂, LaNaO₂, SmNaO₂,(SmLiO₂)_(0.8)(CaOMgO)_(0.2), (LaLi₂)_(0.7)(SrOMgO)_(0.3),(NdLiO₂)_(0.8)(CaMgO)_(0.2), strontium-doped lanthium oxide supported onmagnesium oxide, a material derived by processing a clay mineral withheat to a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the clay material tonon-reversible crystalline and/or glass phases, a material derived byprocessing talc with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe talc material to non-reversible crystalline and/or glass, a materialderived by processing a zeolite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the zeolite material to non-reversiblecrystalline and/or glass phases, a material derived by processingBrucite with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe Brucite material to non-reversible crystalline material, a materialderived by processing a Gibbsite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the clay material to non-reversiblecrystalline material, and combinations thereof.

The clay mineral is selected from the group consisting of amontmorillonite, a ball clay, illite, dickite, halloysite, a mica, azeolite, a koalinite, an illitic clay, pyropholite, Endellite,bentonite, chlorite, and combinations thereof.

The coating on the susceptor can be used as a reactant with a chemicalspecies flow for desired products or with a pollutant species to treatpollutants for producing clean air which can be discharge into theenvironment in accordance with the law of the land.

The coating can be a carbon-containing species that reacts with achemical species flow to produce hydrogen, higher order chemicalspecies, lower order chemical species, carbon monoxide, carbon dioxideor combinations thereof.

The coating can contain a reactant selected from the group consisting ofNa-beta alumina, Li-beta alumina, NaOH, LiOH, CaCO3, Ca(OH)₂,gamma-alumina, alpha-alumina, lithium complexes, a lithium complexpartially adsorbed on partially calcine bauxite, a sodium complexpartially adsorbed on partially calcine bauxite, silica, a cation-dopedsilica or combination thereof, to chemically react with a chemicalspecies flow containing a fluorine species, a chlorine species, a sulfurspecies, and combinations thereof.

The coating also can contain a reactant selected from the groupconsisting of urea, ammonia, cyanuric acid, ammonium carbamate, ammoniumbicarbonate, mixtures of ammonia and ammonium bicarbonate, ammoniumformate, ammoniumoxialate, sources of a nydroxyl radicals, sources ofhydrogen radicals, milk, sugar, molasses, polysaccharides, a reducingagent, and combinations thereof, to chemically react with a chemicalspecies flow containing a nitrogen oxide or nitrogen oxides to produceNitrogen (N₂).

Particle-Size Effects, Materials For The Matrix, Applications, MaterialsMixture, Physical Properties, Atmospheres, Operating Temperature andOther Properties

The invention also is an electromagnetic susceptor for chemicalprocessing comprising a matrix material that surrounds a non-matrixmaterial that is made from a material that is different from the matrixmaterial, wherein:

a. the matrix material is constructed of material having lowerdielectric losses compared to the non-matrix material;

b. the non-matrix material initially absorbs electromagnetic energyapplied to the electromagnetic susceptor to a greater extent than thematrix material;

c. the non-matrix material produces subsequent heat in the matrixmaterial; and

d. the greatest length of measurement of the electromagnetic susceptoris between one nanometer and 10 meters.

The non-matrix material also can produce reflection.

The susceptor can be used in an atmosphere selected from the groupconsisting of a reducing atmosphere, an oxidizing atmosphere, anatmosphere at one atmosphere of pressure, an atmosphere at less than oneatmosphere of pressure, an atmosphere at greater than one atmosphere ofpressure, and combinations thereof.

The susceptor's function can be selected from the group consisting ofdriving chemical reactions, assisting in chemical reactions,polymerization, producing biodiesel through catalysis, synthesizingpharmaceuticals, reducing nitrogen oxides to nitrogen (N₂), reducing NOto nitrogen (N₂), reducing NO₂ to NO, reducing NO₂ to nitrogen (N₂),reducing SO_(x) to sulfur (S), reducing SO₃ to SO₂, reducing SO₄ to SO₂,reducing SO₃ to SO₂, chemical synthesis, sterilization, crackinghydrocarbons, decreasing the activation energy of a chemical process,oxidizing volatile organic compounds, oxidizing carbon monoxide tocarbon dioxide, reducing NOx in the presence of hydrocarbons,synthesizing biodiesel, reforming a hydrocarbon with a hydrogen donorspecies in the presence of H₂O, reforming a hydrocarbon with methane inthe presence of H₂O, reforming a hydrocarbon in the presence of methane,water and carbon dioxide, reforming a hydrocarbon in the presence ofmethane, water, hydrogen and carbon dioxide, reforming a hydrocarbon inthe presence of hydrogen and methane, polymerizing a hydrocarbon in thepresence of metal halides, reducing nitrogen oxides in the presence ofammonia, reducing nitrogen oxides in the presence of ammonium-containingcompounds, treating pollutants to form clean air which can be dischargedinto the environment in accordance to the law of the land, oxidativebond cleavage of a hydrocarbon, non-oxidative bond cleavage of ahydrocarbon, catalysis, field concentration or combination thereof,wherein the reaction occurs in physical phases of matter from the groupconsisting of a plasma, gas, solid, liquid, a fluid containingparticulates, the production of useful energy products, and combinationsthereof.

The operating temperature of the susceptor can be selected from thegroup consisting of operating conditions consisting of a temperaturewhich is above the Curie temperature of all the susceptor's materials, atemperature which is below the Curie temperature of all the susceptor'smaterials, a temperature which is above Curie temperature of thenon-matrix material only, a temperature which is above the Curietemperature of the matrix material only, a temperature which is abovethe Curie temperature of all the susceptor's materials causing increasedabsorption, a temperature which is above the Curie temperature of thenon-matrix material causing increased absorption, a temperature which isabove the Curie temperature of the matrix material causing increasedabsorption, a temperature above the thermal runaway temperature(critical temperature) of at least one of the constituent phases, atemperature which is below the thermal runaway temperature (criticaltemperature) of all the susceptor's constituent phases, a temperaturewhich is below the activation temperature of the intrinsic dielectricconduction species of all the phases present, a temperature which isabove the activation temperature of at least one intrinsic dielectricconducting species of all constituent phases, a temperature which isbelow the activation temperature of all extrinsic dielectric conductingspecies, a temperature which is above the activation temperature of atleast one extrinsic dielectric conducting species of all the constituentphases, and combinations thereof.

The particle size of the non-matrix material through interaction withthe applied electromagnetic energy can provide a utility to effect aphysical property of said susceptor selected from the group consistingof mechanical properties, thermal properties, optical properties of thenon-matrix material, optical properties of the susceptor, absorption ofelectromagnetic energy, reflection of electromagnetic energy,transmission of electromagnetic energy, scattering of electromagneticenergy, electromagnetic properties, corrosive properties, wearproperties, piezoelectric properties, dielectric properties, magneticproperties, electric properties, susceptibility to the appliedelectromagnetic energy, susceptibility to the fluorescentelectromagnetic energy, conductivity, controlling the chemicalcompatibility between the non-matrix material and the matrix material,regulating the temperature of said susceptor, regulating the temperatureof a process, regulating the amount of electromagnetic energy availablefor chemical process, regulating the amount of electromagnetic energyavailable for a physical process, and combinations thereof.

The particle size of the matrix material through interaction with theapplied electromagnetic energy can provide a utility to effect aphysical property of said susceptor selected from the group consistingof mechanical properties, thermal properties, optical properties of thematrix material, optical properties of the susceptor, absorption ofelectromagnetic energy, reflection of electromagnetic energy,transmission of electromagnetic energy, scattering of electromagneticenergy, electromagnetic properties, corrosive properties, wearproperties, piezoelectric properties, dielectric properties, magneticproperties, electric properties, susceptibility to the appliedelectromagnetic energy, susceptibility to the fluorescentelectromagnetic energy, conductivity, controlling the chemicalcompatibility between the non-matrix material and the matrix material,regulating the temperature of said susceptor, regulating the temperatureof a process, regulating the amount of electromagnetic energy availablefor chemical process, regulating the amount of electromagnetic energyavailable for a physical process, and combinations thereof.

The non-matrix material preferably has a particle size of less than theUS Standard Mesh size 325. The particle size of the non-matrix materialcan be selected from the group consisting of mono-modal, multi-modal,heterogeneous and homogeneous particle sizes, and combinations thereof.The particle-size of the matrix material can be selected from the groupconsisting of mono-modal distribution, multi-modal distribution,heterogeneous and homogeneous particle sizes, and combinations thereof.

The matrix material can be selected from the group consisting ofmaterials that are metallic, amorphous, polycrystalline,antiferromagnetic, antiferroelectric, paramagnetic, an artificialdielectric material where the volume fraction of the non-matrix speciesis less that 50 volume percent, an artificial dielectric material wherethe volume fraction of the non-matrix species is equal to or greaterthan 50 volume percent, a material that produces thermionic emissions, amaterial that is thermoelectric, a cermet, a material with a Curietemperature, glassy, metallic, ferrimagnetic, ferroelectric,ferromagnetic, semiconducting, conducting, a solid-state ionicconductor, a non-stoichiometric carbide, a non-stoichiometric oxide, anoxycarbide, an oxynitride, a carbonitride, an intermetallic, ahydroxide, a non-stoichiometric nitride, thermoluminescent, anon-stoichiometric lmenitic structure, fluorescent, a boride, a materialwith low dielectric constant and low dielectric losses, a material witha high dielectric constant and low dielectric losses, a silicide, anitride, an aluminide, a material with a high dielectric constant andhigh dielectric losses, a material with a high dielectric constant andmoderate dielectric losses, a carbide, an oxide, anatase, a sulfide, asulfate, a carbonate, a glass ceramic, photochromatic, thermochromatic,a phase separated glass, an ionic conductor, and combinations thereof.

The matrix material also can be selected from group consisting of FeO,CuO Cu₂O, MnO₂ Mn₂O₅, NiO, Fe₂O₃, Fe₃O₄, CuO—MnO₂, Cu₂O—MnO₂, Li₂O—Cu₂O,Li₂O—CuO, Li₂O—MnO₂, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂,non-stoichiometric titanium oxide, Li₂O—NiO, TiO₂ doped with a divalentcation, TiO₂ doped with a trivalent cation, Fe₂O₃ doped with Ti⁺⁴, TiO,Ti₂O₃, non-stoichiometric zirconia oxide, anatase, beta″alumina,alpha-alumina, Na-beta-alumina, Li-beta-alumina, (Na,Li)-beta-alumina,carbon, graphite, ZnO, CuS, FeS, CoO, calcium aluminate, char, Ni, Co,Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO₃, FeTiO₃, LiNbO₃,MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x), FeTiO_(3-x), andcombinations thereof.

The matrix material can be a composite material.

Defects can be introduced into a crystalline molecular structure of theconstituent materials to effect the susceptor's physical propertiesselected from the group consisting of mechanical properties, thermalproperties, chemical properties, optical properties, magneticproperties, electric properties, property of susceptibility toelectromagnetic energy, conductivity, catalytic properties,electromagnetic properties, and combinations thereof. The defect can beselected from the group consisting of an intrinsic defect, an extrinsicdefect, a defect from cation substitution, a defect from anionsubstitution, and combinations thereof.

The non-matrix material and matrix material can have the same Bravaislattice structure, similar crystalline structure and chemicalcomposition where the non-matrix material contains ionic substitutionwhich produces greater dielectric losses compared to the matrixmaterial. The non-matrix material and matrix material also can have thesame Bravais lattice structure, similar crystalline structure andsimilar chemical composition where at least one phase of the matrixmaterial contains ionic substitution which produces greater dielectriclosses compared to remaining matrix material.

The electromagnetic susceptor can further comprises a barrier coatingbetween the non-matrix material and matrix material to preventdeleterious chemical reaction.

The electromagnetic susceptor also can have a constituent material usedto decrease the power required to obtain the desired operatingtemperature for the desired use and the form of the constituent materialis selected from the group consisting of a coating, non-matrix material,a matrix material, a field concentrator, and combinations thereof.

The susceptor can be used for the adsorption of a chemical species,absorption of a chemical species, or combinations thereof.

The thermal conductivity of the susceptor can be used to control theheat transfer between the dielectric susceptor and chemical species flowand the method of controlling the thermal conductivity of the dielectricsusceptor is selected from the group consisting of controlling the porestructure, controlling the volume of the porosity, using a compositestructure that contains a material with a high thermal conductivity,using a coating on the susceptor that increases the thermal conductivityof the susceptor's surface, grading the pore structure by flamepolishing the outer surface of the dielectric susceptor, andcombinations thereof.

The non-matrix material preferably has a thermal expansion mismatchbetween the non-matrix material and matrix of less than 20%.

The applied electromagnetic energy can initially intercepts thesusceptor in a manner selected from the group consisting of one side ofthe susceptor, more than one side of the susceptor, all sides of thesusceptor, at opposing sides of the susceptor and at adjacent sides ofthe susceptor, and at least one wavelength of applied electromagneticinitially entering the susceptor at set of opposing sides of thesusceptor's surface that have the largest surface area of the susceptorwith also at least one different wavelength of applied electromagneticenergy initially entering the susceptor at a different set of twoopposing sides.

The dimensions of the susceptor can be designed to allow the susceptorto be placed into a cavity that allows for the cavity's dimensions toaccommodate the optical dielectric properties of the appliedelectromagnetic energy or energies so to form a resonate cavity thataccommodates a multiple of ¼ the wavelength of the appliedelectromagnetic energy in the susceptor with respect to the opticalproperties of the susceptor where the multiple is equal to or greaterthan one. At least one dimension of the susceptor can accommodate thelargest wavelength when more then one wavelength is applied to thesusceptor. The dimensions of the susceptor can be made to accommodate aspecific transverse electromagnetic mode.

The susceptor can be placed in a cavity that has a shape that isselected from the group consisting of irregular shaped, orthorhombic,cylindrical, spherical, cubic, hemispherical, ellipsoidal, tubular,equilateral polyhedral, square, rectangular, and polyhedral. The cavityalso can be tuned.

The interaction between the dielectric properties of at least onenon-matrix material and at least one wavelength of the appliedelectromagnetic energy can be selected from the group of consisting ofat least 5% transparency to at least one wavelength of appliedelectromagnetic energy, at least 5% absorption of at least onewavelength of applied electromagnetic energy, at least 5% scattering ofat least one wavelength of applied electromagnetic energy, at least 5%reflection of at least one wavelength of applied electromagnetic energy,and combination thereof.

The interaction between the dielectric properties of the matrix materialand at least one wavelength of the applied electromagnetic energy alsocan be selected from the group of consisting of at least 5% transparencyto at least one wavelength of applied electromagnetic energy, at least5% absorption of at least one wavelength of applied electromagneticenergy, at least 5% reflection of at least one wavelength of appliedelectromagnetic energy, at least 5% scattering of at least onewavelength of applied electromagnetic energy, and combinations thereof.

During the chemical process the temperature of at least part of thematrix material can be greater than the temperature of the non-matrixmaterial. During the chemical process the temperature of at least partof the non-matrix material also can be greater than the temperature ofthe matrix material.

The matrix material can become reflective at a temperature greater than0° C.

The susceptor can be used as a reactant with a chemical species flow fordesired products or with a pollutant species to treat pollutants forproducing clean air which can be discharge into the environment inaccordance with the law of the land.

The susceptor can be a carbon-containing species that reacts with achemical species flow to produce hydrogen, higher order chemicalspecies, lower order chemical species, carbon monoxide, carbon dioxideor combinations thereof.

The susceptor can be a reactant selected from the group consisting ofNa-beta alumina, Li-beta alumina, NaOH, LiOH, CaCO3, Ca(OH)₂,gamma-alumina, alpha-alumina, lithium complexes, a lithium complexpartially adsorbed on partially calcine bauxite, a sodium complexpartially adsorbed on partially calcine bauxite, silica, a cation-dopedsilica or combination thereof, that chemically reacts with a chemicalspecies flow containing a fluorine species, a chlorine species, a sulfurspecies, and combinations thereof.

The susceptor also can a reactant selected from the group consisting ofurea, ammonia, cyanuric acid, ammonium carbamate, ammonium bicarbonate,mixtures of ammonia and ammonium bicarbonate, ammonium formate,ammoniumoxialate, sources of a nydroxyl radicals, sources of hydrogenradicals, milk, sugar, molasses, polysaccharides, a reducing agent, andcombinations thereof, that chemically reacts with a chemical speciesflow containing a nitrogen oxide or nitrogen oxides to produce Nitrogen(N₂).

Clay Systems

The description of a material that is derived by a clay is important.There are at least four (4) ways that a clay can be described:

(1) An extrinsically bonded clay structure: The clay material usingwater or another binding agent for bonding the clay to create astructure. For example, a piece of pottery formed by throwing clay on apotter's wheel;

(2) Non extrinsic bonded clay structure and clay powder: A piece ofpottery held together by van der Waals forces after a drying process hasremoved the bonding water, or dry clay powder;

(3) Crystalline species derived from a clay: Clay, whether as a formedstructure or powder, can be heated above 1000° C. to synthesize anintimate mixture of mullite (an aluminosilicate phase) and a silicaphase; and

(4) An intermediate structure derived from a clay: The clay structurecontains what is known in the trade as water of crystallization. Anintermediate structure that is known as a pseudomorphic structure occurswhen clay is heated above 500° C. Between about 500° C. to about 980° C.or greater, the pseudomorphic structure is the matrix of the originalcrystalline structure of the clay containing large anion vacancies fromremoval of (OH⁻) ions from original crystalline structure. Thispseudomorphic structure is probably metastable up to 1110° C. Thistemperature range is dependent upon atmospheric conditions and particlesize.

The invention also is an electromagnetic susceptor for chemicalprocessing having a matrix material that surrounds a non-matrix materialthat is made from a material that is different from the matrix material,wherein:

a. the matrix material is constructed of a sintered ceramic materialhaving lower dielectric losses compared to the non-matrix material;

b. the non-matrix material initially absorbs electromagnetic energyapplied to the electromagnetic susceptor to a greater extent than thematrix material; and

c. the non-matrix material produces subsequent heat in the matrixmaterial.

The non-matrix material also can produce reflection.

The matrix material can be a sintered ceramic having a composition thatcan have crystalline and glassy phases that is based uponmagnesia-silica chemistry where the summation of the matrix material'sweight fraction of magnesium (Mg), silica (Si) and oxygen (O) is atleast 85% by weight, and comprises:

a. between 5% by weight and 99% by weight of the total weight of MgO inthe matrix material, and up to 100% by weight of the MgO exists as acrystalline phase in a crystalline system selected from the groupconsisting of magnesium silicate, periclase, and combinations thereof;

b. between 5% by weight and 99% by weight of the total weight of SiO₂ inthe matrix material and up to 100% by weight of the SiO₂ exists as acrystalline phase in a crystalline system selected from the groupconsisting of magnesium silicate, silica, and combinations thereof; and

c. the balance of the matrix material's total weight being selected fromcations other that Si and Mg substituted in a crystalline phase selectedfrom the group consisting of magnesium silicate, silica, periclase, andcombinations thereof, at least one cation species other than or inaddition to Mg and Si in a glass phase, a crystalline phase other thanmagnesium silicate, silica and periclase that has at least one othercation species other than or in addition to Mg and Si, and combinationsthereof.

The matrix material also can be a sintered ceramic having a compositionwhich can have crystalline and glassy phases based upon alumina-silicachemistry where the summation of the matrix material's weight fractionof aluminum (Al), silica (Si) and oxygen (O) is at least 80% by weight,and comprises:

a. between 5% by weight and 99% by weight of the total weight of Al₂O₃in the matrix material, and up to 100% by weight of the Al₂O₃ exists asa crystalline phase in a crystalline system selected from the groupconsisting of aluminosilicate, alumina, and combinations thereof;

b. between 5% by weight and 99% by weight of the total weight of SiO₂ inthe matrix material, and up to 100% by weight of the SiO₂ exists as acrystalline phase in a crystalline system selected from the groupconsisting of aluminosilicate, silica, or combinations thereof; and

c. the balance of the matrix material's total weight being selected fromcations other than Al and Si substituted in a crystalline phase selectedfrom the group consisting of an aluminosilicate, an alumina, a silica,and combinations thereof, at least one cation species other than or inaddition to Si and Al in a glass phase, a crystalline phase other thanaluminosilicate, silica and alumina that has at least one other cationspecies other than or in addition to Mg and Si, and combinationsthereof.

The matrix material can be selected from the group consisting ofstabilized zirconia, partially stabilized zirconia, and combinationsthereof.

The electromagnetic susceptor can comprise a matrix material that isnonreflective of electromagnetic energy and that surrounds a non-matrixmaterial that is reflective of electromagnetic energy and that is madefrom a material that is different from the matrix material and furthercomprising a field concentrator and a coating between saidelectromagnetic susceptor and said field concentrator that preventsdeleterious chemical reaction between said electromagnetic susceptor andsaid field concentrator.

The field concentrator can be made from a material that is selected fromthe group consisting of a conductor, semi-conductor, materials with aCurie temperature, and an ionic conducting ceramic. The fieldconcentrator can be of a size that is designed to lessen any deleteriouschemical reaction between materials of construction of theelectromagnetic susceptor and the material of the field concentrator.The field concentrator also can be made from a material that is selectedfrom the group consisting of MnO₂—CuO, Li₂O—NiO, Li₂O—MnO₂, Li₂O—CuO,TiO₂ doped with a divalent cation, and TiO₂ doped with a trivalentcation, Fe₂O₃ with Ti⁺⁴.

The matrix material can be selected from the group of crystalline phasesconsisting of enstatite, clino-enstatite, forsterite, cordierite,periclase, alpha-quartz, beta-quartz, alpha-trydimite, beta′-trydimite,beta″-trydimite, alpha-crystobalite, beta-crystobalite, anorthosilicate, a pyrosilicate, a metasilicate, wollastonite, albite,orthoclase, microcline, sillimanite, alpha-alumina, beta-alumina,gamma-alumina, mullite, olivine, anorthite, and combinations thereof.

At least a part of the matrix material can be a glassy phase selectedgroup consisting of amorphous silica, aluminosilicate glass,aluminosilicate glass with glass modifiers, phosphate-based glass, phaseseparated glass, germanium-based glass, soda-lime-silicate glass,borosilicate glass, sodium silicate glass, calcium silicate glass,soda-lime-aluminosilicate glass, chalcogenide, and combinations thereof.

The matrix material also can be a sintered ceramic having a compositionwhich has crystalline and glassy phases based uponmagnesia-alumina-silica chemistry where the summation of the matrixmaterial's weight fraction of aluminum (Al), magnesium (Mg), silica (Si)and oxygen (O) is at least 80% by weight, comprising:

a. between 5% by weight and 99% by weight of the total weight of Al₂O₃in the matrix material, and up to 100% by weight of the Al₂O₃ exist as acrystalline phase in a crystalline system from the group consisting ofmagnesium aluminosilicate, alumina, aluminosilicate, magnesiumaluminate, and combinations thereof;

b. between 5% by weight and 99% by weight of the total weight of MgO inthe matrix material, and up to 100% by weight of the MgO exists as acrystalline phase in a crystalline system selected from the groupconsisting of magnesium aluminosilicate, magnesium silicate, periclase,magnesium aluminate, and combinations thereof;

c. between 5% by weight and 99% by weight of the total weight SiO₂ inthe matrix material, and up to 100% by weight of the SiO₂ exists as acrystalline phase in a crystalline system selected from the groupconsisting of silica, magnesium aluminosilicate, magnesium silicate, andcombinations thereof; and

d. the balance of the matrix material's total weight being selected fromother than Mg, Al and Si substituted in a crystalline phase in acrystalline system selected from the group consisting ofaluminosilicate, magnesium aluminosilicate, magnesium silicate,magnesium aluminate, alumina, silica, periclase, and combinationsthereof, at least one other cation species other than or in addition toMg, Al and Si in a glass phase, a crystalline phase other than magnesiumaluminosilicate, aluminosilicate, magnesium silicate, magnesiumaluminate, silica, periclase and alumina that has at least one othercation species other than or in addition to Mg, Al, and Si, andcombinations thereof.

The matrix material can be selected from the group consisting ofalumina, aluminosilicate ceramic, magnesium aluminosilicate ceramic,magnesium silicate, calcium silicate, crystalline form of silica,calcium aluminosilicate, clay, zeolite, magnesium oxide, sialon,oxynitride, inorganic glass, organic glass, organic polymer, crystallineorganic polymer, solid solution, ceramic matrix composite, metal matrixcomposite, polymer composite, cordierite, quartz, enstatite, forsterite,steatite, nitride, porcelain, high-temperature porcelain, glass ceramic,phase separated glass, lithium-aluminosilicate, Teflon, organiccopolymer, polycarbonate, polypropylene, polystyrene, polyethylene,polyester, polytetrafluoroethylene, materials derived by processing aclay mineral with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe clay material to non-reversible crystalline and/or glass phases,materials derived by processing talc with heat to a temperature and fortime period above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the talc material to non-reversiblecrystalline and/or glass, a material derived by processing a zeolitewith heat to a temperature and for time period above the temperaturethat the water of crystallization is removed and below a temperature andfor time period that prevent complete transformation of the zeolitematerial to non-reversible crystalline and/or glass phases, materialsderived by processing Brucite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the Brucite material to non-reversiblecrystalline material, materials derived by processing a Gibbsite withheat to a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the clay material tonon-reversible crystalline material, and combinations thereof.

The matrix material can be selected from the group consisting ofthermoluminescent materials, fluorescent materials, low-lossdielectrics, and combinations thereof. The fluorescent materialsfluoresce upon exposure of a dye to the applied electromagnetic energyand the dye is embedded in a matrix that is primarily transparent to theradiation emitted from the dye. The fluorescent materials producefluorescent radiation selected from the group of electromagneticfrequencies consisting of ultraviolet radiation, visible radiation,infrared radiation, and combinations thereof.

The non-matrix material can be selected from the group consisting ofmaterials that are amorphous, metallic, ferrimagnetic, ferroelectric,ferromagnetic, semiconducting, conducting, solid-state ionic conductor,non-stoichiometric carbides, non-stoichiometric oxides, oxycarbides,oxynitrides, carbonitrides, intermetallic, thermoluminescent,fluorescent, borides, silicides, nitrides, aluminides, carbides, oxides,sulfides, composite materials, organic polymeric matrix composites,ceramic matrix composites, metal matrix composites, organic copolymers,amorphous organic polymers, crystalline organic polymers,polycarbonates, polypropylene, polystyrene, polyethylene, polyester,polytetrafluoroethylene, solid solutions, sulfates, non-stoichiometricillmenitic structures, mica, non-stoichiometric zinc oxide,non-stoichiometric nitrides, crystalline forms of silica,antiferromagnetics, antiferroelectrics, materials with low dielectricconstant and low dielectric losses, materials with high dielectricconstant and low dielectric losses, paramagnetics, materials with highdielectric constant and high dielectric losses, materials with a highdielectric constant and moderate dielectric losses, hydroxides,thermochromatics, photochromatics, metal alloys, artificial dielectricmaterials where the volume fraction of the non-matrix species is lessthat 50 volume percent, artificial dielectric materials where the volumefraction of the non-matrix species is equal to or greater than 50 volumepercent, materials that produce thermionic emissions, materials that arethermoelectric, cermet, materials with a Curie temperature, sulfates,anatase, carbonate, materials derived by processing a clay mineral withheat to a temperature and for time period above the temperature that thewater of crystallization is removed and below a temperature and for timeperiod that prevent complete transformation of the clay material tonon-reversible crystalline and/or glass phases, materials derived byprocessing talc with heat to a temperature and for time period above thetemperature that the water of crystallization is removed and below atemperature and for time period that prevent complete transformation ofthe talc material to non-reversible crystalline and/or glass, materialsderived by processing a zeolite with heat to a temperature and for timeperiod above the temperature that the water of crystallization isremoved and below a temperature and for time period that preventcomplete transformation of the zeolite material to non-reversiblecrystalline and/or glass phases, materials derived by processing Brucitewith heat to a temperature and for time period above the temperaturethat the water of crystallization is removed and below a temperature andfor time period that prevent complete transformation of the Brucitematerial to non-reversible crystalline material, materials derived byprocessing a Gibbsite with heat to a temperature and for time periodabove the temperature that the water of crystallization is removed andbelow a temperature and for time period that prevent completetransformation of the clay material to non-reversible crystallinematerial, and combinations thereof. The non-matrix material also can beselected from the group consisting of FeO, CuO Cu₂O, MnO_(s2), Mn₂O₅,NiO, Fe₂O3, Fe₃O₄, CuO—MnO₂, Cu₂O—MnO₂, Li₂O—Cu₂O, Li₂O—CuO, Li₂O—MnO₂,Li₂O—NiO, ZnO, and combinations thereof.

The non-matrix material further can be selected from the groupconsisting, SiC, WC, TiC, TiC_(x-y)O_(y), TiC_(1-x), TiO₂, TiO₂ dopedwith a divalent cation, TiO₂ doped with a trivalent cation, Fe₂O₃ dopedwith Ti⁺⁴, a non-stoichiometric titanium oxide, TiO, Ti₂O₃, anon-stoichiometric zirconia oxide, anatase, beta″-alumina,alpha-alumina, Na-beta-alumina, Li-beta-alumina, (Na, Li)-beta-alumina,a carbon, a graphite, CuS, FeS, CoO, a calcium aluminate, a char, Ni,Co, Fe, NiFe alloy, MgTiO₃, MnTiO₃, NiTiO₃, CoTiO3, FeTiO₃, LiNbO₃,MnTiO_(3-x), NiTiO_(3-x), MgTiO_(3-x), CoTiO_(3-x), FeTiO_(3-x), quartz,a crystalline form of silica, and combinations thereof.

The applied electromagnetic energy can be a radiation selected from thegroup consisting of ultra-violet, infrared, microwave, visible, radiofrequency, 915 MHz, 2.45 GHz, a variable frequency source, andcombinations thereof.

The structure of the susceptor can be selected from the group consistingof chiral-shaped, spire-like shaped, helical shaped, rod-like shaped,plate-like shaped, acicular shaped, spherical shaped, ellipsoidalshaped, disc-shaped, irregular-shaped, plate-like shaped, a shape of aspiral antenna species for at least one wavelength of appliedelectromagnetic energy, a shape of an antenna specified for at least onwavelength of applied electromagnetic energy, needle-like shaped, twistshaped, rotini shaped, a woven structure and honeycomb-like structure,multi-cell structure, cylindrical shaped, tubular shaped, a reticulatedstructure, a foamed structure, a capillary structure, and combinationsthereof.

The shape of the non-matrix material can be selected from a groupconsisting of chiral, spire-like, helical, rod-like, plate-like,acicular, spherical, ellipsoidal, disc-shaped, irregular-shaped,plate-like, needle-like, and twist.

The interaction between the dielectric properties of the susceptor andat least one wavelength of the applied electromagnetic energy can beselected from the group of interactions with applied electromagneticenergy consisting of at least 5% transparent to at least one wavelengthof applied electromagnetic energy, at least 5% scattering to at leastone wavelength of applied electromagnetic energy, at least 5% absorptiveof at least one wavelength of applied electromagnetic energy, at least5% reflective of at least one wavelength of applied electromagneticenergy, and combinations thereof.

The non-matrix material can have a volume fraction greater than 50% andless than 98%. The non-matrix material can have a volume fractiongreater than 0.001% and less than or equal to 50%.

The susceptor can further comprise a coating, a catalyst, and/or a fieldconcentrator.

The susceptor can have a volume fraction of porosity and pore-sizedistribution which are used to control the physical properties of thesusceptor selected from the group consisting of dielectric properties,thermal properties, mechanical properties, optical properties, corrosiveproperties, magnetic properties, electric properties, conductiveproperties, absorptive properties, susceptibility of appliedelectromagnetic energy, wear properties, and combinations thereof.

The matrix material also can be a sintered ceramic having a compositionwhich has crystalline and glassy phases based uponmagnesia-alumina-silica chemistry where the summation of the matrixmaterial's weight fraction of aluminum (Al), magnesium (Mg), silica (Si)and oxygen (O) is at least 80% by weight, wherein:

a. the weight percent of Al₂O₃ in the matrix material is between 5% byweight and 99% by weight, and up to 100% by weight of the Al₂O₃ existsas a crystalline phase in a crystalline system from the group consistingof magnesium aluminosilicate, alumina, aluminosilicate, magnesiumaluminate, and combinations thereof;

b. the weight percent of MgO in the matrix material is between 5% byweight and 99% by weight, and up to 100% by weight of the MgO exists asa crystalline phase in a crystalline system selected from the groupconsisting of magnesium aluminosilicate, magnesium silicate, periclase,magnesium aluminate, and combinations thereof;

c. the weight percent SiO₂ in the matrix material is between 5% byweight and 99% by weight, and up to 100% by weight of the SiO₂ exists asa crystalline phase in a crystalline system selected from the groupconsisting of silica, magnesium aluminosilicate, magnesium silicate, andcombinations thereof; and

d. the balance of the matrix material's weight percent is cationsubstitution other than Mg, Al and Si in a crystalline phase in acrystalline system selected from the group consisting ofaluminosilicate, magnesium aluminosilicate, magnesium silicate,magnesium aluminate, alumina, silica, periclase, and combinationsthereof, at least one other cation species other than or in addition toMg, Al and Si in a glass phase, a crystalline phase other than magnesiumaluminosilicate, aluminosilicate, magnesium silicate, magnesiumaluminate, silica, periclase and alumina that has at least one othercation species other than or in addition to Mg, Al, and Si, andcombinations thereof.

The matrix material also can be a sintered ceramic having a compositionwhich has crystalline and glassy phases based upon calcia-alumina-silicachemistry where the summation of the matrix material's weight fractionof aluminum (Al), calcium (Ca), silica (Si) and oxygen (O) is at least80% by weight, wherein:

a. The weight percent of Al₂O₃ in the matrix material is between 5% byweight and 99% by weight, and up to 100% by weight the Al₂O₃ exist as acrystalline phase in a crystalline system from the group consisting ofcalcium aluminosilicate, alumina, calcium aluminate, aluminosilicate,and combinations thereof;

b. the weight percent of CaO in the matrix material is between 5% byweight and 99% by weight, and up to 100% by weight of the CaO exists asa crystalline phase in a crystalline system selected from the groupconsisting of calcium aluminosilicate, calcium silicate, calciumaluminate, calcia, and combinations thereof;

c. the weight percent SiO₂ in the matrix material is between 5% byweight and 99% by weight, and up to 100% by weight of the SiO₂ exists asa crystalline phase in a crystalline system selected from the groupconsisting of silica, calcium aluminosilicate, calcium silicate, andcombinations thereof; and

d. the balance of the matrix material's weight is cation substitutionother than Ca, Al and Si in a crystalline phase in a crystalline systemselected from the group consisting of aluminosilicate, calciumaluminosilicate, calcium aluminate, calcium silicate, alumina, calcia,silica, and combinations thereof, at least one other cation speciesother than or in addition to Ca, Al and Si in a glass phase, acrystalline phase other than a calcium aluminosilicate, calciumaluminate, aluminosilicate, calcium silicate, silica, calcia and aluminathat has at least one other cation species other than or in addition toCa, Al, and Si, and combinations thereof.

Ozone Production

The invention also includes a method of producing ozone from interactionon an electromagnetic susceptor between field concentrators on theelectromagnetic susceptor and applied electromagnetic energy applied tothe susceptor, comprising the steps of:

a. controlling the distance between field concentrators on theelectromagnetic susceptor;

b. using a low loss, low dielectric constant material of constructionfor the electromagnetic susceptor; and

c. applying electromagnetic energy to the electromagnetic susceptor toproduce ozone.

A second embodiment of the method of producing ozone from interaction onan electromagnetic susceptor, comprises the steps of:

a. providing an electromagnetic susceptor having a matrix material thatis nonreflective of electromagnetic energy and that surrounds anon-matrix material that is reflective of electromagnetic energy andthat is made from a material that is different from the matrix material,wherein the non-matrix material has exposed surfaces;

b. controlling the distance between the exposed surfaces of thenon-matrix material;

c. using a matrix material that has a low dielectric losses and lowdielectric constant; and

d. applying electromagnetic energy to the electromagnetic susceptor toproduce ozone.

Energy Product

The invention further is a useful energy product created by a processwhere a chemical species flow passes through a macroscopic artificialdielectric structure for a gas-permeable susceptor consisting of firstregions in the structure that are primarily transparent to appliedelectromagnetic energy and second regions in the structure that are notprimarily transparent to applied electromagnetic energy; wherein:

-   -   (a) the first regions are discontinuously interspersed between        and among the second regions,    -   (b) the transmission of the applied electromagnetic energy by        these said first regions provides a means for increase        interaction between the applied electromagnetic energy and the        chemical species flow,    -   (c) the transmission of the applied electromagnetic energy by        these said first regions provides a means for increased        interaction between the applied electromagnetic energy and the        second regions in the gas-permeable susceptor to interact with        said second regions, and    -   (d) the distance between each of said first regions and volume        fraction of the said first regions assists the applied        electromagnetic energy to penetrating the structure and        interacting volumetrically with the susceptor and the reactant        chemical species flow passing through the susceptor and allows        for the synthesis a useful energy product.

The invention further is a useful energy product created by a processwhere a chemical species flow passes through a macroscopic artificialdielectric structure for a gas-permeable susceptor consisting of:

-   -   first regions in the structure that are primarily absorptive to        applied electromagnetic energy;    -   second regions in the structure that are not primarily        transparent to applied electromagnetic energy;        wherein:    -   (a) the first regions are discontinuously interspersed between        and among the second regions,    -   (b) the transmission of the applied electromagnetic energy by        these said first regions provides a means for increase        interaction between the applied electromagnetic energy and the        chemical species flow,    -   (c) the transmission of the applied electromagnetic energy by        these said first regions provides a means for increased        interaction between the applied electromagnetic energy and the        second regions in the gas-permeable susceptor to interact with        said second regions, and    -   (d) the distance between each of said first regions and volume        fraction of the said first regions assists the applied        electromagnetic energy to penetrating the structure and        interacting volumetrically with the susceptor and the reactant        chemical species flow passing through the susceptor and allows        for the synthesis a useful energy product.

The useful energy product of the present invention can be a refinedproduct from crude oil, a refined product from shale oil, a refinedproduct from oil sands, a refined oil from petroleum pitch, a refinedoil product, a refined product from heavy petroleum fractions, biofuel,bioethanol, ethanol, biodiesel, biogasoline, biokerosene, hydrogen,syngas, and a higher-order chemical species. Additionally, the refinedproduct can be obtain from a process consisting of hydrocracking ahydrocarbon, cracking a hydrocarbon, desulphurization of a hydrocarbon,demetalization of a hydrocarbon, removal of water, cleavage of carboxylgroup, esterification, transesterification, etherification,sterilization, evaporation or combinations thereof.

In producing the useful energy product, the reactant chemical speciesflow comprises at least one of canola oil, sunflower oil, soybean oil,rapeseed oil, mustard seed oil, palm oil, corn oil, soya oil, linseedoil, peanut oil, coconut oil, corn oil, olive oil, animal fat, yellowgrease, animal tallow, pork fat, pork oil, chicken fat, chicken oil,mutton fat, mutton oil, beef fat, beef oil, petroleum, hydrogen, shaleoil, tar sand, petroleum pitch, petroleum, kerogen, tar, residuum aheavy crude oil, a sugar, a starch, methane, methanol and combinationsthereof.

Preferably, the second regions are the chemical species flow. The secondregions chemicals species flow can be selected from the group consistingof a plant species, an animal fat, a shale oil species, a tar sandspecies, residuum, heavy oil, petroleum pitch, a kerogen containingmaterial, a solid hydrocarbon, a coal species, and a heavy crude.

Preferably, the first regions are a material chosen from the groupconsisting of a ceramic, a glass, a organic polymer, polypropylene,polycarbonate, a fluorinated hydrocarbon, Teflon, fused silica, adielectric loss ceramic, a low dielectric loss glass, a low dielectricloss porcelain, a clay, a materials with a low dielectric loss and lowdielectric constant, aerogel, a foam, and combinations thereof.

The first regions preferably are shaped in a form selected from thegroup consisting of shapes of a irregular shaped granular, aspiral-like, spherical, orthogonal, twist-like, chiral shape, spire-likeshape, cylindrical shape, tubular shape, helical shape, rod-like shape,plate-like shape, acicular shape, spherical shape, ellipsoidal shape,disc-shaped shape, irregular-shaped shape, plate-like shape, needle-likeshape, twist shape, a shape like a pasta rotini twist and combinationthereof. The size of the first regions preferably are between 0.00001and 30 meters. The volume fraction of the first regions preferably isgreater than 5%.

The first regions preferably are arranged in a 3-dimension arrayconsisting of an array structure selected from the group consisting ofat least one homogenous distribution, at least one random distribution,at least one inhomogeneous, and a combination there of.

The applied electromagnetic energy is selected from the group consistingof radio frequency, microwave, ultraviolet, visible, infrared, pulsedenergy, continuous energy, a variable frequency application, andcombination thereof.

The invention further is a method to crack a hydrocarbon comprising thesteps of:

-   -   a) applied electromagnetic source applies a variable frequency        mode of operations to the hydrocarbon material;    -   b) the hydrocarbon material absorbs the applied electromagnetic        energy over the range of the variable frequency applied; and    -   c) the original hydrocarbon is cracked into at least one smaller        molecular species.

The method to crack a hydrocarbon further comprises introducing hydrogento assist in the cracking process, wherein the hydrocarbon preferably isselected from the group consisting of a petroleum species, a kerogenspecies, a shale oil species, a tar sand species, a plant oil, an animalfat, a plant species, a heavy crude, a tar, residuum and a hydrocarbonwith containing twelve or more carbons. If a plant oil is used, itpreferably is cracked in situ.

In the method to crack hydrocarbon, the hydrocarbon preferably is mixedwith at least one material that is primarily transparent to the appliedvariable frequency electromagnetic energy source. This materialpreferably is either solid or liquid. If a solid, this materialpreferably is selected from the group consisting of fused silica,alumina, a porcelain, polymer, Teflon, polypropylene, polycarbonate, aglass or combination thereof.

Additionally, this material preferably is shaped in a form selected fromthe group consisting of shapes of a irregular shaped granular, aspiral-like, spherical, orthogonal, twist-like, chiral shape, spire-likeshape, cylindrical shape, tubular shape, helical shape, rod-like shape,plate-like shape, acicular shape, spherical shape, ellipsoidal shape,disc-shaped shape, irregular-shaped shape, plate-like shape, needle-likeshape, twist shape, and a shape like a pasta rotini twist.

The above detailed description of the preferred embodiments, examples,and the appended figures are for illustrative purposes only and are notintended to limit the scope and spirit of the invention, and itsequivalents, as defined by the appended claims. One skilled in the artwill recognize that many variations can be made to the inventiondisclosed in this specification without departing from the scope andspirit of the invention.

1. A process for creating a useful energy product from a chemicalspecies flow comprising passing the chemical species flow through amacroscopic artificial dielectric structure for a gas-permeablesusceptor, and subjecting the structure to applied electromagneticenergy, the structure consisting of first regions and second regions,the first regions and the second regions having different depths ofpenetration of the applied electromagnetic energy, the depth ofpenetration of the first regions being greater than the depth ofpenetration of the second regions, wherein: (a) the first regions arediscontinuously interspersed at least a certain distance from each otherbetween and among the second regions, (b) the transmission of theapplied electromagnetic energy by the first regions provides a means forincrease interaction between the applied electromagnetic energy and thechemical species flow, (c) the transmission of the appliedelectromagnetic energy by the first regions provides a means forincreased interaction between the applied electromagnetic energy and thesecond regions in the gas-permeable susceptor to interact with thesecond regions, and (d) the distance between each of the first regionsand a volume fraction of the of the structure that the first regionsmake up assists the applied electromagnetic energy to penetrate thestructure and to interact volumetrically with the susceptor and thechemical species flow passing through the susceptor and allows for thesynthesis of the useful energy product.
 2. The process as claimed inclaim 1 wherein the useful energy product is selected from the groupconsisting of a refined product from crude oil, a refined product fromshale oil, a refined product from oil sands, a refined oil frompetroleum pitch, a refined oil product, a refined product from heavypetroleum fractions, biofuel, bioethanol, ethanol, biodiesel,biogasoline, biokerosene, hydrogen, syngas, a higher-order chemicalspecies, and combinations thereof.
 3. The process as claimed in claim 2wherein the refined product is obtain from a process consisting ofhydrocracking a hydrocarbon, cracking a hydrocarbon, desulphurization ofa hydrocarbon, demetalization of a hydrocarbon, removal of water,cleavage of carboxyl group, esterfication, transesterification,etherification, sterilization, evaporation, and combinations thereof. 4.The process as claimed in claim 1, wherein the chemical species flowcomprises at least one component selected from the group consisting ofcanola oil, sunflower oil, soybean oil, rapeseed oil, mustard seed oil,palm oil, corn oil, soya oil, linseed oil, peanut oil, coconut oil, cornoil, olive oil, animal fat, yellow grease, animal tallow, pork fat, porkoil, chicken fat, chicken oil, mutton fat, mutton oil, beef fat, beefoil, petroleum, hydrogen, shale oil, tar sand, petroleum pitch,petroleum, kerogen, tar, residuum a heavy crude oil, a sugar, a starch,methane, methanol, and combinations thereof.
 5. The process as claimedin claim 1, wherein the second regions are the chemical species flow. 6.The process as claimed in claim 5, wherein the chemicals species flow isselected from the group consisting of a plant species, and animal fat, ashale oil species, a tar sand species, residuum, heavy oil, petroleumpitch, a kerogen containing material, a solid hydrocarbon, a coalspecies, a heavy crude, and combinations thereof.
 7. The process asclaimed in claim 1, wherein the distance between each of the firstregions and a volume fraction of the structure that the first regionsmake up assists the applied electromagnetic energy to penetrate thestructure and to interact volumetrically with the susceptor and thechemical species flow to a greater extent in the combined volume of thefirst regions, the second regions and the chemical species flow whencompared to the penetration of the applied electromagnetic energy in thecombined volume of either the second regions and the chemical speciesflow or only the chemical species flow as the chemical species flowpasses through the first regions and allows for the synthesis of theuseful energy product.
 8. The process as claimed in claim 1, wherein thephysical arrangement and volume fraction of the first regions of thesusceptor creates a greater surface area for interaction between theapplied electromagnetic energy and any secondary electromagnetic energyproduced from the interaction of the applied electromagnetic energy witheither the first regions, the second regions, the chemical species flow,the useful energy product or any combination thereof, and the chemicalspecies flow to a greater extent in the combined volume of the firstregions, the second regions and the chemical species flow when comparedto the penetration of the applied electromagnetic energy in the combinedvolume of either the second regions and the chemical species flow oronly the chemical species flow as the chemical species flow passesthrough the first regions and allows for the synthesis of the usefulenergy product.
 9. A system for creating a useful energy product from achemical species flow, the system comprising: a macroscopic artificialdielectric structure for a gas-permeable susceptor, the structureconsisting of first regions and second regions, the first regions andthe second regions having different depths of penetration of appliedelectromagnetic energy, the depth of penetration of the first regionsbeing greater than the depth of penetration of the second regions, andflowing the chemical species flow through the gas-permeable susceptor,and subjecting the chemical species flow to the applied electromagneticenergy within the structure, wherein: (a) the first regions arediscontinuously interspersed at least a certain distance from each otherbetween and among the second regions, (b) the transmission of theapplied electromagnetic energy by the first regions provides a means forincrease interaction between the applied electromagnetic energy and thechemical species flow, (c) the transmission of the appliedelectromagnetic energy by the first regions provides a means forincreased interaction between the applied electromagnetic energy and thesecond regions in the gas-permeable susceptor to interact with thesecond regions, and (d) the distance between each of the first regionsand a volume fraction of the structure that the first regions make upassists the applied electromagnetic energy to penetrate the structureand to interact volumetrically with the susceptor and the chemicalspecies flow passing through the susceptor and allows for the synthesisof the useful energy product.
 10. The system as claimed in claim 9wherein the useful energy product is selected from the group consistingof a refined product from crude oil, a refined product from shale oil, arefined product from oil sands, a refined oil from petroleum pitch, arefined oil product, a refined product from heavy petroleum fractions,biofuel, bioethanol, ethanol, biodiesel, biogasoline, biokerosene,hydrogen, syngas, a higher-order chemical species, and combinationsthereof.
 11. The system as claimed in claim 10 wherein the refinedproduct is obtain from a process consisting of hydrocracking ahydrocarbon, cracking a hydrocarbon, desulphurization of a hydrocarbon,demetalization of a hydrocarbon, removal of water, cleavage of carboxylgroup, esterfication, transesterification, etherification,sterilization, evaporation, and combinations thereof.
 12. The system asclaimed in claim 9, wherein the chemical species flow comprises at leastone component selected from the group consisting of canola oil,sunflower oil, soybean oil, rapeseed oil, mustard seed oil, palm oil,corn oil, soya oil, linseed oil, peanut oil, coconut oil, corn oil,olive oil, animal fat, yellow grease, animal tallow, pork fat, pork oil,chicken fat, chicken oil, mutton fat, mutton oil, beef fat, beef oil,petroleum, hydrogen, shale oil, tar sand, petroleum pitch, petroleum,kerogen, tar, residuum a heavy crude oil, a sugar, a starch, methane,methanol, and combinations thereof.
 13. The system as claimed in claim9, wherein the second regions are the chemical species flow.
 14. Thesystem as claimed in claim 13, wherein the chemicals species flow isselected from the group consisting of a plant species, and animal fat, ashale oil species, a tar sand species, residuum, heavy oil, petroleumpitch, a kerogen containing material, a solid hydrocarbon, a coalspecies, a heavy crude, and combinations thereof.
 15. The system asclaimed in claim 9, wherein the distance between each of the firstregions and a volume fraction of the structure that the first regionsmake up assists the applied electromagnetic energy to penetrate thestructure and to interact volumetrically with the susceptor and thechemical species flow to a greater extent in the combined volume of thefirst regions, the second regions and the chemical species flow whencompared to the penetration of the applied electromagnetic energy in thecombined volume of either the second regions and the chemical speciesflow or only the chemical species flow as the chemical species flowpasses through the first regions and allows for the synthesis of theuseful energy product.
 16. The system as claimed in claim 9, wherein thephysical arrangement and volume fraction of the first regions of thesusceptor creates a greater surface area for interaction between theapplied electromagnetic energy and any secondary electromagnetic energyproduced from the interaction of the applied electromagnetic energy witheither the first regions, the second regions, the chemical species flow,the useful energy product or any combination thereof, and the chemicalspecies flow to a greater extent in the combined volume of the firstregions, the second regions and the chemical species flow when comparedto the penetration of the applied electromagnetic energy in the combinedvolume of either the second regions and the chemical species flow oronly the chemical species flow as the chemical species flow passesthrough the first regions and allows for the synthesis of the usefulenergy product.
 17. A device for creating a useful energy product from achemical species flow, the device comprising a macroscopic artificialdielectric structure for a gas-permeable susceptor for subjecting thechemical species flow to applied electromagnetic energy, the structureconsisting of first regions and second regions, the first regions andthe second regions having different depths of penetration of appliedelectromagnetic energy, the depth of penetration of the first regionsbeing greater than the depth of penetration of the second regions,wherein: (a) the first regions are discontinuously interspersed at leasta certain distance from each other between and among the second regions,(b) the transmission of the applied electromagnetic energy by the firstregions provides a means for increase interaction between the appliedelectromagnetic energy and the chemical species flow, (c) thetransmission of the applied electromagnetic energy by the first regionsprovides a means for increased interaction between the appliedelectromagnetic energy and the second regions in the gas-permeablesusceptor to interact with the second regions, and (d) the distancebetween each of the first regions and a volume fraction of the structurethat the first regions make up assists the applied electromagneticenergy to penetrate the structure and to interact volumetrically withthe susceptor and the chemical species flow passing through thesusceptor and allows for the synthesis of the useful energy product. 18.The device as claimed in claim 17 wherein the useful energy product isselected from the group consisting of a refined product from crude oil,a refined product from shale oil, a refined product from oil sands, arefined oil from petroleum pitch, a refined oil product, a refinedproduct from heavy petroleum fractions, biofuel, bioethanol, ethanol,biodiesel, biogasoline, biokerosene, hydrogen, syngas, a higher-orderchemical species, and combinations thereof.
 19. The device as claimed inclaim 18 wherein the refined product is obtain from a process consistingof hydrocracking a hydrocarbon, cracking a hydrocarbon, desulphurizationof a hydrocarbon, demetalization of a hydrocarbon, removal of water,cleavage of carboxyl group, esterfication, transesterification,etherification, sterilization, evaporation, and combinations thereof.20. The device as claimed in claim 17, wherein the chemical species flowcomprises at least one component selected from the group consisting ofcanola oil, sunflower oil, soybean oil, rapeseed oil, mustard seed oil,palm oil, corn oil, soya oil, linseed oil, peanut oil, coconut oil, cornoil, olive oil, animal fat, yellow grease, animal tallow, pork fat, porkoil, chicken fat, chicken oil, mutton fat, mutton oil, beef fat, beefoil, petroleum, hydrogen, shale oil, tar sand, petroleum pitch,petroleum, kerogen, tar, residuum a heavy crude oil, a sugar, a starch,methane, methanol, and combinations thereof.
 21. The device as claimedin claim 17, wherein the second regions are the chemical species flow.22. The device as claimed in claim 21, wherein the chemicals speciesflow is selected from the group consisting of a plant species, andanimal fat, a shale oil species, a tar sand species, residuum, heavyoil, petroleum pitch, a kerogen containing material, a solidhydrocarbon, a coal species, a heavy crude, and combinations thereof.23. The device as claimed in claim 17, wherein the distance between eachof the first regions and a volume fraction of the structure that thefirst regions make up assists the applied electromagnetic energy topenetrate the structure and to interact volumetrically with thesusceptor and the chemical species flow to a greater extent in thecombined volume of the first regions, the second regions and thechemical species flow when compared to the penetration of the appliedelectromagnetic energy in the combined volume of either the secondregions and the chemical species flow or only the chemical species flowas the chemical species flow passes through the first regions and allowsfor the synthesis of the useful energy product.
 24. The device asclaimed in claim 17, wherein the physical arrangement and volumefraction of the first regions of the susceptor creates a greater surfacearea for interaction between the applied electromagnetic energy and anysecondary electromagnetic energy produced from the interaction of theapplied electromagnetic energy with either the first regions, the secondregions, the chemical species flow, the useful energy product or anycombination thereof, and the chemical species flow to a greater extentin the combined volume of the first regions, the second regions and thechemical species flow when compared to the penetration of the appliedelectromagnetic energy in the combined volume of either the secondregions and the chemical species flow or only the chemical species flowas the chemical species flow passes through the first regions and allowsfor the synthesis of the useful energy product.